Hydrocarbon hydroprocessing using bulk catalyst composition

ABSTRACT

The invention relates to a method for hydroprocessing hydrocarbon feedstocks, said process comprising contacting a hydrocarbon feedstock under hydroprocessing conditions with a bulk catalyst composition comprising bulk metal particles that comprise at least one Group VIII non-noble metal, at least one Group VIB metal and nanoparticles. The bulk metal catalyst composition comprises bulk metal particles that may be prepared by a manufacturing process comprising the steps of combining in a reaction mixture (i) dispersible nanoparticles having a dimension of less than about 1 μm upon being dispersed in a liquid, (ii) at least one Group VIII non-noble metal compound, (iii) at least one Group VIB metal compound, and (iv) a protic liquid; and reacting the at least one Group VIII non-noble metal compound and the at least one Group VIB metal in the presence of the nanoparticles.

This application claims the benefit of U.S. Provisional Application61/005,224 filed Dec. 4, 2007.

TECHNICAL BACKGROUND OF THE INVENTION

The invention relates to a method for hydroprocessing hydrocarbonfeedstocks, said process comprising contacting a hydrocarbon feedstockunder hydroprocessing conditions with a bulk catalyst compositioncomprising bulk metal particles that comprise at least one Group VIIInon-noble metal, at least one Group VIB metal and nanoparticles.

DESCRIPTION OF THE PRIOR ART

The hydroprocessing of hydrocarbon feedstocks generally encompasses allprocesses in which a hydrocarbon feedstock is reacted with hydrogen inthe presence of a catalyst and under hydroprocessing conditions,typically, at elevated temperature and elevated pressure. The termhydroprocessing includes, but is not limited to, processes such ashydrogenation, hydrodesulfurization, hydrodenitrogenation,hydrodemetallization, hydrodearomatization, hydroisomerization,hydrodewaxing, hydrocracking and mild hydrocracking.

In general, conventional hydroprocessing catalysts are composed of acarrier (or support) with a Group VIB metal component and a Group VIIInon-noble metal component deposited thereon. Such catalysts may beprepared by impregnating a carrier with aqueous solutions of compoundsof the desired metals, followed by one or more drying and/or calcinationsteps.

Alternative techniques for the preparation of the “supported” catalystsare described in U.S. Pat. No. 4,113,605—where inter alia nickelcarbonate is reacted with MoO₃ to form crystalline nickel molybdate,which is subsequently mixed and extruded with alumina—and in GermanPatent No. DE 3029266, where nickel carbonate is mixed with WO₃ and theresulting composition is mixed with alumina impregnated with compoundssuch as nickel nitrate and ammonium tungstate.

A significant amount of attention has recently been directed to theprovision of catalysts which can be applied without a carrier, generallyreferred to as bulk catalysts. WO 99/03578 describes a method for thepreparation of bulk hydroprocessing catalysts compositions comprisingbulk metal oxide particles having one Group VIII non-noble metal and twoGroup VIB metals by reacting and co-precipitating nickel, molybdenum,and tungsten compounds in the absence of sulfides.

WO 00/41810 describes a method for the preparation of a hydroprocessingcatalyst comprising bulk metal oxide particles wherein one or more GroupVIII non-noble metal and two or more Group VIB metals are reacted in aprotic liquid, wherein the metal compounds are at least partly in thesolute state (i.e., dissolved) during the reaction. The prior art alsodiscloses producing the hydroprocessing catalyst in a convenient formfor use in a hydroprocessing process by shaping, for example byextrusion, and by compositing the obtained bulk metal oxide particleswith small quantities of further materials, for example binder material,to facilitate shaping and to provide mechanical strength to a shapedcatalyst.

Although the bulk catalyst compositions described in the prior art havean excellent hydroprocessing activity, there exists a continuous need inthe art to develop novel bulk catalyst compositions with furtherimproved hydroprocessing activity in particular in hydrodesulfurisation(HDS), as well as hydrodenitrogenation (HDN), and hydrogenation ofparticular target hydrocarbon feedstocks, such as diesel and vacuum gasoil (VGO).

For instance, WO 00/41810 describes bulk catalysts having bulk metaloxide particles comprising at least one Group VIII metal and at least 2Group VIB metals with varying ratios of Group VIII to Group VIB metals.The examples describe that increasing hydrodesulfurisation (HDS)activity is obtained at increasing molar ratios of Group VIII metal overGroup VIB metals. This document indicates in particular that, for bulkmetal catalysts having one Group VIII metal and one Group VIB metal, itis very difficult to obtain a suitably active catalyst at a Group VIIIto Group VIB metal molar ratio below 1.25. Furthermore, at metal molarratios below about 1.1 to 1, a completely different crystal structure isobtained that was not active at all. From a theoretical point of view,it is believed that such large amounts of Group VIII metal, althoughadvantageous or even necessary in the process of the preparation of thecatalyst, may not be necessary, or not fully necessary, in the activesulfided bulk catalyst employed in the hydrotreatment of a hydrocarbonfeedstock. While high Group VIII to Group VIB metal molar ratios appearto be useful during catalyst synthesis, excessive amounts of Group VIIImetals seem to only add unnecessary weight and to reduce the activityper unit weight of the bulk catalyst composition once the bulk metaloxide particles are sulfided. Thus, there is a desire to find higheractivity catalyst, in particular for bulk catalysts comprising at leastone Group VIII and at least one Group VIB metal that can be producedwith low Group VIII to Group VIB metal molar ratios.

SUMMARY OF THE INVENTION

Accordingly, a bulk catalyst composition is provided comprising bulkmetal oxide particles having (i) dispersible nanoparticles having adimension of less than about 1 μm upon being dispersed in a liquid, (ii)at least one Group VIII non-noble metal compound, and (iii) at least oneGroup VIB metal compound; as well as a process for preparing such bulkmetal oxide particles comprising the steps of combining in a reactionmixture (i) dispersible nanoparticles having a dimension of less thanabout 1 μm upon being dispersed in a liquid, (ii) at least one GroupVIII non-noble metal compound, (iii) at least one Group VIB metalcompound, and (iv) a protic liquid; and reacting the at least one GroupVIII non-noble metal compound and the at least one Group VIB metalcompound.

The process preferably comprises: (a) preparing a first suspension of atleast one Group VIII non-noble metal compounds in a protic liquid; (b)preparing a second suspension of at least one Group VIB metal compoundsin a protic liquid and (c) adding the first and second suspensionstogether, wherein at least one of the first or second suspensionscomprises dispersible nanoparticles having a dimension of less thanabout 1 μm upon being dispersed in a liquid. More preferably, at least aportion of the nanoparticles is included in the first suspension of theGroup VIII non-noble metal compound. Most preferably, at least a portionof the nanoparticles is included in a first suspension that comprises atleast one of nickel carbonate, nickel hydroxy-carbonate, cobaltcarbonate and cobalt hydroxy-carbonate.

In one embodiment, the Group VIB or VIII metal compound is prepared byprecipitation in the presence of the nanoparticles. Preferably, nickel(hydroxy-) carbonate and cobalt (hydroxy-) carbonate are prepared byprecipitation in the presence of nanoparticles, preferably of syntheticclay mineral.

This process can also be used to make bulk metal oxide particlescomprising at least one Group VIII non-noble metal compound and at leasttwo Group VIB metal compounds.

In another embodiment of the process according to the invention, thereaction mixture further comprises a Group V metal compound, preferablya niobium compound. The Group V metal has been found to promote, evenwhen present in relatively low amounts, the formation of an activecatalyst especially in critical composition ranges, for example at lowGroup VIII to Group VIB metal molar ratio. The term “active catalyst”means a catalyst having a high HDS and/or HDN activity.

This invention is also directed to a bulk catalyst compositioncomprising bulk metal oxide catalyst particles comprising at least oneGroup VIII non-noble metal, at least one Group VIB metal and dispersiblenanoparticles having a dimension of less than about 1 μm upon beingdispersed in a liquid, obtainable by the process according to theinvention. Further, in accordance with another aspect of the inventionthere is provided a bulk catalyst composition comprising bulk metaloxide catalyst particles which comprise at least one Group VIIInon-noble metal and at least one Group VIB metal, said Group VIII andGroup VIB metals representing from about 50 wt. % to about 99.5 wt. %,calculated as oxides, of the total weight of the bulk catalystcomposition, the metals being present in the bulk catalyst compositionin their oxidic state and/or their sulfidic state, and from about 0.5wt. % to about 15 wt. % (based of the total weight of the bulk metaloxide catalyst particles) of nanoparticles. The invention furtherrelates to a sulfided bulk catalyst obtainable by sulfiding the abovedescribed bulk catalyst composition comprising bulk metal oxide catalystparticles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a typical X-ray diffraction (XRD) pattern (two-theta vs.intensity) for a metal oxide catalyst of the invention comprisingtungsten.

FIG. 2 shows a comparison of XRD patterns for catalysts containingvarious clay particles.

DETAILED DESCRIPTION OF THE INVENTION

It has been found that a bulk catalyst composition comprising bulk metalparticles prepared by combining and reacting, in the presence ofdispersible nanoparticles having a dimension of less than 1 μm in itsdispersed state, at least one Group VIII non-noble metal compound withat least one Group VIB metal compound in a reaction mixture with aprotic liquid have many advantages over corresponding catalystscomprising bulk metal particles prepared without the nanoparticles. Forexample, it was found that bulk metal catalysts prepared withnanoparticles having a dimension of less than 1 μm in their dispersedstate provide catalysts having a significantly higher hydroprocessingactivity than the same catalyst prepared without such nanoparticles inthe reaction mixture. Further, the desired highly active metal oxidebulk particle structure is formed in a significantly shorter time thanin the absence of the nanoparticles, even at low Group VIII to Group VIBmetal molar ratios.

The various embodiments relating to these findings are described belowin further detail.

Compounds and Materials (I) Nanoparticles

Since the mixed metal oxide/sulfide particles formed during the catalystpreparation process can also be nanoparticles, the term nanoparticles asused herein does not refer to metal oxide nanoparticles that may formduring the catalyst synthesis process, but to other nanoparticlesdeliberately added to the reaction mixture used to synthesize the mixedmetal oxide particles. In a preferred embodiment, the nanoparticles areclay mineral nanoparticles, preferably synthetic clay mineralnanoparticles, having a dimension of less than about 1 μm. Morepreferably, the nanoparticles have a largest dimension, in threecoordinate space, of less than about 1 μm, preferably less than 500 nm,more preferably less than 250 nm, and even more preferably less than 100nm. The nanoparticles preferably have a smallest dimension, in threecoordinate space, of less than 25 nm, preferably less than 10 nm, evenmore preferably less than 5 nm, and even more preferably less than 1 nm.A nanoparticle's dimensions can be determined by TEM, light scatteringmethods, or equivalent methods known in the art, as described hereafter.Conveniently, at least 50 wt. %, such as at least 70 wt. % of thenanoparticles have a largest dimension of less than about 1 μm.

In addition to definitions described above, the term “nanoparticles” asused herein encompasses particles of any shape having appropriatedimensions and, as such, include spherical, polyhedral, nanofiber anddisc-like nanoparticles.

Preferably the nanoparticles used in the present invention are clayminerals, more preferably synthetic clay minerals, that can providedisc-like nanoparticles when dispersed in the protic liquid of theinvention and which thus present a flat or quasi-flat surface during thereaction of the metal compounds which form the bulk metal oxideparticles. More preferably clay minerals, which can provide disc-likeparticles having a surface area greater than about 250 m²/g, mostpreferably greater than about 350 m²/g are desirable. Such clay mineralsinclude synthetic 2:1 type clays and natural and synthetic layeredsilicic acids. The nanoparticles are preferably a clay mineral selectedfrom the group consisting of synthetic clays of the smectite family,layered silicic acids, kaolinite, laponite, halloysite and mixturesthereof.

Synthetic 2:1 types clays suitable for inclusion in this invention—suchas fluorohectorite, laponite and fluoromicas—include those of thesmectite family with the crystal structure consisting of nanometer thicksheets of aluminium (Al) octahedra sandwiched between two silicon (Si)tetrahedron sheets. These three-sheet layers are stacked with a van deWaals gap between the layers. Isomorphic substitution of Al withmagnesium (Mg), iron (Fe) or lithium (Li) in the octahedra sheets and/orSi with Al in the tetrahedron sheets gives each three sheet layer anoverall negative charge which is counterbalanced by exchangeable metalcations in the interlayer space such as sodium (Na), calcium (Ca), Mg,Fe and Li.

Synthetic layered silicic acids suitable for inclusion in thisinvention—such as kanemite, makatite, octasilicate, magadite andkenyaite—are clays that consist mainly of silicon tetrahedron sheetswith different layer thickness. They exhibit similar intercalationchemistry to the aforementioned smectites; furthermore, as they possesshigh purity and structural properties that are complimentary to thesesmectite clays, this facilitates their use in combination with saidsmectites.

The intercalation chemistry of both the synthetic smectite clays and thesynthetic layered silicic acids allows them to be chemically modified tobe compatible with the further metal compounds of the bulk catalystcomposition.

Synthetic 2:1 type clays and layered silicic acids are typicallyavailable commercially as powders. These powder minerals and other claysare preferably exfoliated and/or delaminated into disc-likenanoparticles before use in the process according to the invention.Preferably this is carried out by dispersion of the powders in a liquid,preferably water, for a sufficiently long period of time to exfoliateand/or delaminate into disc-like nanoparticles. Without wishing to bebound by theory, the formation of disc-like nanoparticles from suchpowders is believed to occur by the following process: i) a wetting ofthe powders to form aggregated particle stacks, each stack beinganalogous to a column of coins with each coin being a layer of the claystructure; ii) dispersion of said aggregated stacks into individualparticle stacks (“secondary particles”); iii) hydration of intercalatedsodium ions within the stacks; and iv) separation into individualparticles (“primary particles”).

It is to be noted that both the non-aggregated individual stacks(secondary particles) and the primary particles can be nanoparticleswithin the meaning of this invention. The primary particles of thesedisc-shaped clay minerals are generally characterized by a thicknessranging from about 0.1 and about 1.5 nm, a lateral dimension of lessthan about 100 nm, an aspect ratio of about 100 to about 1500 andsurface areas greater than about 250 m²/g. However, it is desirable inthe present invention to use clays which can be provided as—ordelaminated/exfoliated into—primary and secondary particles which arecharacterized by a surface area ranging from about 350 to about 1000m²/g, and wherein the (constituent) primary particles have a thicknessof about 1 nm, and a lateral dimension of less than about 100 nm.

As such, it is preferred in the present invention that the nanoparticlescomprise a synthetic clay of the smectite family. More preferably, thenanoparticles comprise greater than about 70 wt. %, preferably greaterthan about 90 wt. %, laponite, based on the total weight of thenanoparticles. Most preferably, the nanoparticles consist essentially oflaponite.

The clay mineral nanoparticles may also be prepared as organoclays.Organoclays are manufactured by modifying clay with quaternary amines, atype of surfactant that contains a nitrogen ion. The nitrogen end of thequaternary amine, the hydrophilic end, is positively charged, and can beion-exchanged for sodium or calcium. The amines used typically are ofthe long chain type with from about 12 to about 18 carbon atoms. If acertain minimum percentage, typically about 30% t, of the clay surfaceis coated with these amines, the clay becomes hydrophobic. With certainamines, the clay can be made organophilic.

Other Compounds and Materials

The process for the preparation of bulk catalysts according to theinvention combines in a reaction mixture with a protic liquid, metalcompounds and nanoparticles, and reacts the metals in the presence ofthe nanoparticles. The protic liquid can be any protic liquid which doesnot interfere with the reactions of the metal compounds or thedispersion of the nanoparticles. Examples include water, carboxylicacids, and alcohols such as methanol, ethanol or mixtures thereof.Preferred protic liquids are mixtures of water and other protic liquids,such as mixtures of an alcohol and water, and a more preferred proticliquid is water alone.

It will be evident that different protic liquids can be appliedsimultaneously in the process of this invention. For instance, it ispossible to add a suspension of a metal compound in ethanol to anaqueous solution of another metal compound. In some cases, a metalcompound can be used which dissolves in its own water ofcrystallization. The water of crystallization serves as protic liquid inthis case.

At least one Group VIII non-noble metal compound and at least one GroupVIB metal compound are used in the process of the invention. SuitableGroup VIB metals include chromium, molybdenum, tungsten, or mixturesthereof, with a combination of molybdenum and tungsten being mostpreferred. Suitable Group VIII non-noble metals include iron, cobalt,nickel, or mixtures thereof, preferably cobalt and/or nickel.Preferably, a combination of metal compounds comprising either i) nickeland tungsten; ii) nickel and molybdenum, iii) nickel, molybdenum, andtungsten; iv) cobalt and tungsten; v) cobalt and molybdenum; vi) cobalt,molybdenum, and tungsten; or vii) nickel, cobalt, molybdenum andtungsten is used in the process of the invention.

In a preferred embodiment, nickel and cobalt make up at least about 50wt. %, more preferably at least about 70 wt. %, still more preferably atleast about 90 wt. % of the total of Group VIII non-noble metalcompounds, calculated as oxides. It is even more preferred for the GroupVIII non-noble metal compound to consist essentially of nickel and/orcobalt.

In another preferred embodiment, molybdenum and tungsten represent atleast about 50 wt. %, more preferably at least about 70 wt. %, stillmore preferably at least about 90 wt. % of the total of Group VIB metalcompounds, calculated as trioxides. It is even more preferred for theGroup VIB metal compound to consist essentially of a mixture ofmolybdenum and tungsten.

The molar ratio of Group VIB metal to Group VIII non-noble metalsapplied in the process of the invention generally ranges from about 10:1to about 1:10 and preferably ranges from about 3:1 to about 1:3. Themolar ratio of the different Group VIB metals to one another generallyis not critical. The same holds when more than one Group VIII non-noblemetal is applied. When molybdenum and tungsten are used as Group VIBmetals, the molybdenum:tungsten molar ratio preferably lies in the rangeof about 9:1 to about 1:19, more preferably about 3:1 to about 1:9, mostpreferably about 3:1 to about 1:6.

In another embodiment, the bulk catalyst according to the inventioncomprises a Group V metal, preferably niobium. Preferably, they Group Vmetal is present in an amount ranging from about 0.1 to about 10 mole %(relative to the total of the Group VIB metals), more preferably fromabout 0.1 to about 9 mole %, more preferably from about 0.1 to about 8,even more preferably from about 0.1 to about 7, and most preferably fromabout 0.1 to about 5 mole %. The Group V metal has been found topromote, even when present in relatively low amounts, the formation ofan active catalyst especially in critical composition ranges, forexample at low Group VIII to Group VIB metal molar ratio. The presenceof a Group V metal, preferably niobium, is particularly preferred wherethe molar ratio of Group VIII metal over Group VIB metal is below about1.5:1, even more preferred when it is below about 1.4:1, about 1.3:1, oreven below about 1.2:1. Particularly preferred catalysts according toinvention comprise Group VIII metals Co, Ni, or a mixture of Co and Ni,and Group VIB metals W, Mo, or a mixture of W and Mo, preferably only Niand W, in a metal molar ratio below about 1.2:1, and further comprisebetween about 0.1 and about 5 mole % (relative to the total of the GroupVIB metals, wherein all metals are expressed as oxides) of a Group Vmetal, preferably niobium, and about 0.5 to about 5 wt % (relative tothe total weight of the bulk metal oxide particle) of a syntheticnanoclay, wherein the Group VIII, Group VIB and Group V metals form atleast about 95 wt % (based on oxides) of the total of the metalcompounds in the bulk catalyst particles and at least about 50 wt %,preferably at least about 70 wt % relative to the total weight of thebulk catalyst composition.

If the protic liquid is water, the solubility of the Group VIIInon-noble metal compounds and Group VIB metal compounds which are atleast partly in the solid state during the process of the inventiongenerally is less than about 0.05 mol/100 ml water at 18° C. This may becontrasted with the high solubility of the selected compounds of, forexample, GB 1 282 950.

If the protic liquid is water, suitable Group VIII non-noble metalcompounds which are at least partly in the solid state during theprocess of the invention comprise Group VIII non-noble metal compoundswith a low solubility in water such as citrates, oxalates, carbonates,hydroxy-carbonates, hydroxides, phosphates, phosphides, sulfides,aluminates, molybdates, tungstates, oxides or mixtures thereof.Preferably, Group VIII non-noble metal compounds which are at leastpartly in the solid state during the process of the invention comprise,and more preferably consist essentially of, oxalates, carbonates,hydroxy-carbonates, hydroxides, phosphates, molybdates, tungstates,oxides, or mixtures thereof, with hydroxy-carbonates and carbonatesbeing most preferred. Generally, the molar ratio between the hydroxygroups and the carbonate groups in the hydroxy-carbonate lies in therange from 0 to about 4, preferably from 0 to about 2, more preferablyfrom 0 to about 1 and most preferably from about 0.1 to about 0.8.

If the protic liquid is water, suitable nickel and cobalt compoundswhich are at least partly in the solid state during the process of theinvention comprise slightly soluble nickel or cobalt or mixednickel-cobalt compounds such as oxalates, citrates, aluminates,carbonates, hydroxy-carbonates, hydroxides, molybdates, phosphates,phosphides, sulfides, tungstates, oxides, or mixtures thereof.Preferably, the nickel or cobalt compound comprises, and more preferablyconsists essentially, of oxalates, citrates, carbonates,hydroxy-carbonates, hydroxides, molybdates, phosphates, tungstates,oxides, or mixtures thereof, with nickel and/or cobalthydroxy-carbonate, nickel and/or cobalt hydroxide, nickel and/or cobaltcarbonate, or mixtures thereof being most preferred. Generally, themolar ratio between the hydroxy groups and the carbonate groups in thenickel or cobalt or nickel-cobalt hydroxy-carbonate lies in the range of0 to about 4, preferably 0 to about 2, more preferably 0 to about 1 andmost preferably about 0.1 to about 0.8. Suitable iron compounds whichare at least partly in the solid state are iron(II) citrate, ironcarbonate, hydroxy-carbonate, hydroxide, phosphate, phosphide, sulfide,oxide, or mixtures thereof, with iron(II) citrate, iron carbonate,hydroxy-carbonate, hydroxide, phosphate, oxide, or mixtures thereofbeing preferred.

If the protic liquid is water, suitable low water-solubility Group VIBmetal compounds which are thus at least partly in the solid state duringcontacting include di- and trioxides, carbides, nitrides, aluminiumsalts, acids, sulfides or mixtures thereof. Of this group, it ispreferred that the Group VIB metal compounds consist essentially of, di-and trioxides, acids or mixtures thereof.

Suitable molybdenum compounds which are at least partly in the solidstate during the process of the invention comprise water-insolublemolybdenum compounds such as molybdenum di- and trioxide, molybdenumsulfide, molybdenum carbide, molybdenum nitride, aluminium molybdate,molybdic acids (e.g. H₂MoO₄), ammonium phosphomolybdate, or mixturesthereof, with molybdic acid and molybdenum di- and trioxide beingpreferred.

Finally, suitable tungsten compounds which are at least partly in thesolid state during the process of the invention comprise water-insolubletungsten compounds, such as tungsten di- and trioxide, tungsten sulfide(WS₂ and WS₃), tungsten carbide, ortho-tungstic acid (H₂WO₄*H₂O),tungsten nitride, aluminium tungstate (also meta- or polytungstate),ammonium phosphotungstate, or mixtures thereof, with ortho-tungstic acidand tungsten di- and trioxide being preferred.

All the above compounds generally are commercially available or can beprepared by, for example, precipitation. In particular nickelhydroxy-carbonate can be prepared from a nickel chloride, sulfate, ornitrate solution by adding an appropriate amount of sodium carbonate. Itis generally known to the skilled person to choose the precipitationconditions in such a way as to obtain the desired morphology and textureof the resultant precipitate, and more particularly to control theparticle size (surface area) of the precipitate.

In general, metal compounds which mainly contain C, O and/or H inaddition to the metal are preferred because they are less detrimental tothe environment. Group VIII non-noble metal carbonates andhydroxy-carbonate are preferred metal compounds to be added at leastpartly in the solid state because when carbonate or hydroxy-carbonate isapplied, CO₂ evolves and positively influences the pH of the reactionmixture. Further, because the carbonate is transformed into CO₂ and doesnot end up in that waste water, it is possible to recycle the wastewater. Consequently, no washing step is necessary to remove undesiredanions from the resulting bulk metal oxide particles.

Preferred Group VIII non-noble metal compounds to be added in the solutestate comprise water-soluble Group VIII non-noble metal salts such asnitrates, sulfates, acetates, chlorides, formates, hypophosphites andmixtures thereof. Examples include water-soluble nickel and/or cobaltcompounds, e.g., water-soluble nickel and/or cobalt salts such asnitrates, sulfates, acetates, chlorides, formates, or mixtures thereofof nickel and/or cobalt as well as nickel hypophosphite. Suitable ironcompounds to be added in the solute state comprise iron acetate,chloride, formate, nitrate, sulfate, or mixtures thereof.

Suitable Group VIB metal compounds to be added in the solute stateinclude water-soluble Group VIB metal salts such as normal ammonium oralkali metal monomolybdates and tungstates as well as water-solubleisopoly-compounds of molybdenum and tungsten, such as metatungstic acid,or water-soluble heteropoly compounds of molybdenum or tungsten furthercomprising, e.g., P, Si, Ni, or Co or combinations thereof. Suitablewater-soluble isopoly- and heteropoly compounds are described inMolybdenum Chemicals, Chemical data series, Bulletin Cdb-14, February1969 and in Molybdenum Chemicals, Chemical data series, BulletinCdb-12a-revised, November 1969. Suitable water-soluble chromiumcompounds include normal chromates, isopolychromates and ammoniumchromium sulfate.

Preferred combinations of metal compounds are a Group VIII non-noblemetal hydroxy-carbonate and/or carbonate, such as nickel or cobalthydroxy-carbonate and/or carbonate, with a Group VIB metal oxide and/ora Group VIB acid, such as the combination of tungstic acid andmolybdenum oxide, or the combination of molybdenum trioxide and tungstentrioxide, or a Group VIII hydroxy-carbonate and/or carbonate, such asnickel or cobalt hydroxy carbonate and/or carbonate, with Group VIBmetal salts, such as ammonium dimolybdate, ammonium heptamolybdate, andammonium metatungstate. It is considered that the skilled person wouldbe able to select further suitable combinations of metal compounds.

Preparation of the Catalyst of the Invention (A) Preparation of BulkMetal Oxide Particles

An aspect of the present invention is directed to a process forpreparing a bulk catalyst composition comprising bulk metal oxidecatalyst particles comprising at least one Group VIII non-noble metaland at least one Group VIB metal, which process comprises combining andreacting at least one Group VIII non-noble metal compound with at leastone Group VIB metal compound in a reaction mixture with a protic liquid:wherein the reaction occurs in the presence of dispersiblenanoparticles, preferably nanoparticles of clay mineral, thenanoparticles being characterized by having a dimension of less than 1μm when in its dispersed state.

Although it is possible for the process of this invention to beperformed by combination and reaction of all metal components being inthe solution state—as described in the disclosure of WO99/03578 which isherein incorporated by reference—it is preferred that at least one ofthe metal compounds remains at least partly in the solid state duringthe entire process. The term “at least partly in the solid state” asused herein means that at least part of the metal compound is present asa solid metal compound and, optionally, another part of the metalcompound is present as a solution of this metal compound in the proticliquid. A typical example of this is a suspension of a metal compound ina protic liquid in which the metal is at least partly present as asolid, and optionally partly dissolved in the protic liquid. Thisaforementioned “entire process” comprises combining and reacting themetal compounds. More particularly, it comprises adding the metalcompounds to each other and simultaneously and/or thereafter reactingthem.

Without wishing to be bound by theory, it is believed that this reactioncan even take place if all metal compounds are virtually completely inthe solid state; due to the presence of the protic liquid a smallfraction of the metal compounds can dissolve, interact and consequentlyreact. The protic liquid is responsible for the transport of dissolvedmetal compounds and therefore the presence of a protic liquid during theprocess of the present invention is considered essential. The reactiontime in this process is relatively long, preferably at least about 4hours. However, due to the presence of nanoparticles the desired activestructure is formed in a significantly shorter time than in the absenceof the nanoparticles.

The embodiment of the invention wherein at least one metal compound isat least partly in the solid state during the process of the inventioncan take place in several ways. In this respect, it is considered, forexample, that processes wherein i) a metal compound which is at leastpartly in solid state is combined with a metal compound which is in thesolute state; ii) one of the metal compounds is added at least partly inthe solid state and two metal compounds are added in the solute state;and iii) two metal compounds are added at least partly in the solidstate to one metal compound in the solute state, are within the scope ofthis embodiment of the invention. With the term “in the solute state” isimplied that the whole amount of this metal compound is added as asolution of this metal compound in the protic liquid. However, a fourth(iv) and preferred alternative is that all metal compounds to becombined in the process of the invention are applied at least partly inthe solid state; this preferred embodiment reduces and ideallyeliminates those anionic species (such as nitrate) and cationic species(such as ammonium ions) which are required for dissolution of the metalcompounds in the protic liquid but which are not incorporated into theresultant mixed metal reaction product.

Within these alternatives all orders of addition of the metal compoundsare possible. For example, that metal compound which is to remain atleast partly in the solid state during the entire process may beprepared first as a suspension of the metal compound in a protic liquidto which added simultaneously or sequentially, solution(s) and/orfurther suspension(s) comprising dissolved and/or suspended furthermetal compound(s) in the protic liquid. Equally, it is also possible tofirst prepare a solution of a first metal component and thensubsequently add the required suspension(s) of the partly solid statemetal compound(s) and optionally further solution(s) eithersimultaneously or sequentially. However it is preferred that all GroupVIII non-noble metal compounds are combined simultaneously and all GroupVIB metal compounds are combined simultaneously and the resulting twomixtures are subsequently combined.

In all these cases any suspension comprising a metal compound can beprepared by suspending a solid metal compound in the protic liquid.However, it is also possible to prepare the suspension by precipitatinga solid metal compound in a protic liquid or (co)precipitating metalcompounds where more than one metal compound is to remain at leastpartly in the solid state during the entire process. The further metalcompounds may then be added directly in solution, in slurry or per se tothe suspension resulting from this (co-) precipitation. Alternatively,the further metal compounds may be added:

-   -   i) to a dry precipitate or co-precipitate after that resulting        precipitate has been treated by solid/liquid separation,        followed by the optional steps of drying and/or thermally        treating;    -   ii) to the precipitate of step i) above that has been wetted; or    -   iii) to the precipitate of step i) or step ii) above that has        been reslurried in a protic liquid.

Regardless of whether the metal components are combined and reacted inthe solute state or combined and reacted with at least one metalcompound being at least partly in the solid state, the reaction betweenthe metal compounds must occur in the presence of nanoparticles. Thenanoparticles are preferably combined with the metals as a suspension inan aqueous liquid. The nanoparticles may be added to solutions orsuspensions of individual metal compounds prior to the combinations ofsaid compounds with further metal compounds or to thesuspensions/solutions of already combined metal compounds. It ispreferred that the nanoparticles are admixed in a suspension of the or ametal compound which is to remain at least partly in the solid stateduring the entire process. Where that suspension of the metal compoundhas been prepared by precipitation it is further preferred that theprecipitation occurs in the presence of the nanoparticles, preferably ofsynthetic clay mineral nanoparticles.

In accordance with an embodiment of the invention, at least a fractionand preferably all of the nanoparticles to be added are included in asuspension of nickel and/or cobalt hydroxy-carbonate or carbonate. Morepreferably these nickel and/or cobalt compounds have been prepared bythe aforementioned precipitation reactions.

Without wishing to be bound by theory, the nanoparticles may act asnuclei on which the metal compound, preferably nickel and/or cobalt(hydroxyl-) carbonate, precipitates. The nanoparticles and the nickeland/or cobalt compounds formed during the reaction are thus intimatelyassociated during formation of the bulk metal particles.

Preferably, at least about 1 wt. %, even more preferably at least about10 wt. %, and still more preferably at least about 15 wt. % of a metalcompound is added in the solid state during the process of theinvention, based on the total weight of all Group VIB and Group VIIInon-noble metal compounds, calculated as metal oxides. When it isdesired to obtain a high yield, that is a high amount of the bulk metaloxide particles, the use of metal compounds of which a high amountremains in the solid state during the process of the invention may bethe preferred method. In that case, low amounts of metal compoundsremain dissolved in the mother liquid and the amount of metal compoundsending up in the waste water during the subsequent solid-liquidseparation is decreased. Any loss of metal compounds can be avoidedcompletely if the mother liquid resulting from solid-liquid separationis recycled in the process of the present invention. It is noted that itis a particular advantage of the process of the present invention that,compared to a catalyst preparation based on a co-precipitationprocess—where anions and cations like ammonium can accumulate in themother liquor—the amount of waste water can be considerably reduced.

In a preferred process the at least one, preferably all metal compoundremains at least partly in the solid state during the process of theinvention. Because in this embodiment the reactivity is not very high,it is preferred that the compounds are slightly soluble. Depending onthe reactivity of the metal compounds, preferably at least about 0.01wt. %, more preferably at least about 0.05 wt. %, and most preferably atleast about 0.1 wt. % of all metal compounds initially employed in theprocess of the invention are in dissolved state in reaction conditions(based on the total weight of all metal compounds, calculated as metaloxides). In this way, proper contacting of the metal compounds isensured.

It has been found that the morphology and the texture of the metalcompound(s) which remain at least partly in the solid state during theprocess of the invention can be retained to some extent during theprocess of the present invention. Consequently, by using metal compoundparticles with a certain morphology and texture, the morphology and thetexture of the bulk metal oxide particles contained in the final bulkcatalyst composition can be controlled at least to some extent.“Morphology and texture” in the context of the present invention referto pore volume, pore size distribution, surface area, particle form andparticle size. Morphologic properties can be preserved by keeping atleast a part of the raw material at least partly in the solid statemeans, for example by controlling the acidity (pH), for example byreducing the addition of acid such that not all of the metal speciesdissolve (e.g., when Ni carbonate, Mo oxide or tungstic acid is used).

Generally the surface area of the bulk metal oxide particles is at leastabout 60%, preferably at least about 70%, and more preferably at leastabout 80% of the surface area of the metal compound which remains atleast partly in the solid state during the process of the invention. Thesurface area is expressed herein as surface area per weight of thismetal compound, calculated as metal oxide. Further, the median porediameter (determined by nitrogen adsorption) of the oxidic bulk metalparticles is at least about 40% and preferably at least about 50% of themedian pore diameter of the metal compound which remains at least partlyin the solid state during the process of the invention. Furthermore, thepore volume (determined by nitrogen adsorption) in the oxidic metalparticles generally is at least about 40% and preferably at least about50% of the pore volume of the metal compound which remains at leastpartly in the solid state during the process of the invention, with thepore volume being expressed herein as the volume of pores per weight ofthis metal compound, calculated as metal oxide.

The retention of the particle size generally is dependent on the extentof mechanical damage undergone by the oxidic bulk metal particles duringprocessing, especially during steps such as mixing or kneading. Theparticle diameter can be retained to a high extent if these treatmentsare short and gentle. In this case, the median particle diameter of theoxidic bulk metal particles generally is at least about 80% andpreferably at least about 90% of the median particle diameter of themetal compound which remains at least partly in the solid state duringthe process of the invention. The particle size can also be affected bytreatments such as spray-drying, especially if further materials arepresent. It is within the capability of the skilled person to selectsuitable conditions in order to control the particle size distributionduring such treatments.

When a metal compound which is added at least partly in the solid stateand which has a large median particle diameter is selected, it isthought that the other metal compounds will only react with the outerlayer of the large metal compound particle. In this case, so-called“core-shell” structured bulk metal oxide particles result (which will bedescribed in greater detail herein below).

An appropriate morphology and texture of the metal compound(s) can beachieved either by applying suitable preformed metal compounds or bypreparing these metal compounds by means of the above-describedprecipitation or re-crystallization or any other technique known by theskilled person under such conditions that a suitable morphology andtexture are obtained. A proper selection of appropriate precipitationconditions can be made by routine experimentation.

To obtain a final bulk catalyst composition with high catalyticactivity, it is preferred that the metal compound or compounds which areat least partly in the solid state during the process of the inventionare porous metal compounds. It is desired that the total pore volume andthe pore size distribution of these metal compounds are broadly similarto those of conventional hydroprocessing catalysts. Conventionalhydroprocessing catalysts generally have a pore volume of about 0.05 toabout 5 ml/g, preferably of about 0.1 to about 4 ml/g, more preferablyof about 0.1 to about 3 ml/g, and most preferably of about 0.1 to about2 ml/g, as determined by mercury or water porosimetry. Further,conventional hydroprocessing catalysts generally have a surface area ofat least about 10 m²/g, more preferably of at least about 50 m²/g, andmost preferably of at least about 100 m²/g, as determined via the B.E.T.method.

The median particle diameter of the metal compound or compounds whichare at least partly in the solid state during the process of theinvention is preferably is in the range from about 0.5 μm to about 5000μm, more preferably from about 1 μm to about 500 μm, and most preferablyfrom about 2 μm to about 150 μm. Generally, the smaller the particlesize of the metal compounds, the higher their reactivity; in principlemetal compounds with particle sizes below the aforementioned preferredlower limits would be desirable embodiments of the present invention butfor health, safety, and environmental reasons, the handling of suchsmall particles requires special precautions and is thus not preferred.

Because of the presence of nano-sized particles during the preparationof the bulk metal particles, the particle size distribution and the poresize distribution of the bulk metal particles shifts towards smallerparticle diameters, compared to bulk metal particles prepared in theabsence of such nanoparticles. Preferably the catalyst composition has apore size distribution wherein at least 75 percent of the total porevolume is in pores of diameter from about 20 angstroms below the modepore diameter to about 20 angstroms above the mode pore diameter, lessthan 10 percent of said total pore volume is in pores of diameter lessthan 60 angstroms and greater than 3 percent to less than 10 percent ofsaid total pore volume is in pores of diameter greater than 110angstroms, and said mode pore diameter of said composition is in therange from about 70 to about 90 angstroms.

Typically, the surface area increases as a result of the presence of thenanoparticles by at least 20%, more preferably at least 30%, even morepreferably at least 50%. Also the pore volume decreases withnanoparticle addition. The pore diameter has been found to decrease bymore than 20%, or even more than 30%, or more than 50%, whennanoparticles are used during preparation of the bulk multimetallicparticles. Preferably however, for VGO hydrotreatment, the mean porediameter (MPD) should not decrease below a value of about 7 nm to retainsufficiently high catalyst performance. In view of this effect and thefact that the activity improvement appears to level off at highnanoparticle content, the amount of nanoparticles added to the reactionmixture is preferably less than about 10 wt. %, relative to the totalamount of metals used, calculated as metal oxides.

In the following, preferred process conditions during the combination ofthe metal compounds and the (subsequent) reaction step will bedescribed:

a) Combination of the Metal Compounds:

The process conditions during the combination of the metal compoundsgenerally are not critical. It is possible to add all compounds atambient temperature at their natural pH (if a suspension or solution isapplied). Generally, it is preferred to keep the temperature of theadded metal compounds below the atmospheric boiling point of thereaction mixture to ensure easy and safe handling of the compoundsduring the addition. However, if desired, temperatures above theatmospheric boiling point of the reaction mixture or different pH valuesmay be applied. If the reaction step is carried out at increasedtemperature, the suspensions and optionally solutions which are added tothe reaction mixture generally can be pre-heated to an increasedtemperature which can be equal to the reaction temperature.

As has been mentioned above, the addition of one or more metal compoundscan also be carried out while already combined metal compounds reactwith each other. In this case, the combination of the metal compoundsand the reaction thereof overlap and constitute a single process step.

b) Reaction Step:

The reaction can be monitored by conventional techniques such as IRspectroscopy or Raman spectroscopy, wherein the reaction is indicated bysignal changes. In some cases, it is also possible to monitor thereaction by monitoring changes in the pH of the reaction mixture.Further, the completeness of the reaction can be monitored by X-raydiffraction. This will be described in more detail under the heading“Bulk catalyst composition of the invention.”

During and/or after their addition, the metal compounds together withthe nanoparticles, preferably the clay mineral nanoparticles, areagitated at a certain temperature for a period of time to allow thereaction to take place. The reaction temperature is preferably in therange of about 0° to about 300° C., more preferably about 50° to about300° C., even more preferably about 70° to about 200° C., and mostpreferably in the range of about 70° to about 180° C. If the temperatureis below the atmospheric boiling point of the reaction mixture, theprocess generally is carried out at atmospheric pressure. Above thistemperature, the reaction generally is carried out at increasedpressure, preferably in an autoclave and/or static mixer.

Typically, the mixture is kept at its natural pH during the reactionstep; said pH is preferably in the range of about 0 to about 12, morepreferably in the range of about 1 to about 10, and even more preferablyin the range of about 3 to about 8. As has been set out above, it ispreferred that the pH and the temperature are chosen in such a way thatnot all the metals are dissolved during the reaction step.

The reaction time may lie in the range of about 1 minute to several daysdepending on the reaction route chosen, but will generally range fromabout 1 minute to about 100 hours. In the process wherein at least oneof the metal compounds is at least partly in the solid state during thereaction, preferably about 1 hour to about 30 hours, more preferablyabout 4 to about 30 hours, even more preferably about 10 to about 25hours and more preferably about 15 hours to about 25 hours. As has beenmentioned above, the reaction time depends on the temperature.

After the reaction step, if necessary, the solid can be separated fromany protic liquid that may remain using, for example filtration. Theprocess of the present invention can be carried out both as a batchprocess and as a continuous process.

(B) Subsequent Process Steps

It is noted that the bulk metal particles resulting from the processdescribed above under (A) are metal oxide particles Following theprocess described above under (A), the bulk metal particles may besubjected to one or more of the following process steps before beingused in hydroprocessing processes:

-   -   (i) compositing with further materials selected from the group        of binder materials, binder precursor materials, conventional        hydroprocessing catalysts, cracking compounds,        phosphorus-containing compounds, boron-containing compounds,        silicon-containing compounds, fluorine-containing compounds,        additional transition metals, rare earth metals or mixtures        thereof,    -   (ii) spray-drying, (flash) drying, milling, kneading,        slurry-mixing, dry or wet mixing, or combinations thereof,    -   iii) shaping,    -   (iv) drying and/or thermally treating, and    -   (v) sulfiding.        The listing of these process steps as (i) to (v) is for        convenience only; it is not a statement that these processes are        constrained to be performed in this order. These process steps        will be explained in more detail in the following:

Process Step (i)

The aforementioned further compositing materials can be performed at aplurality of stages during the preparation of the bulk metal particles.However, because any addition of further materials should not affect theinteraction between the metal compounds and the nanoparticles, it ispreferred that the Group VIB, Group VIII non-noble metal compounds andthe nanoparticles are combined and preferably at least partly reacted tobulk metal particles before being combined with these further materials.

These materials can be added in the dry state, either thermally treatedor not, in the wetted and/or suspended state and/or as a solution. Theymay be added prior to any step (ii) and/or during and/or subsequent toany step (ii) but preferably prior to a final shaping step (iii).Further additives may be added, for example by impregnation, aftershaping (these are not referred to as further compositing materials)

Preferably, the material is added subsequent to the preparation of thebulk metal particles and prior to spray-drying or any alternativetechnique, or, if spray-drying or the alternative techniques are notapplied, prior to shaping. Optionally, the bulk metal particles preparedas described above can be subjected to a solid-liquid separation beforebeing composited with the material. After solid-liquid separation,optionally, a washing step can be included. Further, it is possible tothermally treat the bulk catalyst particles after an optionalsolid-liquid separation and drying step and prior to its beingcomposited with the material.

In all the above-described process alternatives, the term “compositingthe bulk metal particles with a material” means that the material isadded to the bulk metal particles or vice versa and the resultingcomposition is mixed. Mixing is preferably done in the presence of aliquid (“wet mixing”). This improves the mechanical strength of thefinal bulk catalyst composition.

It has been found that compositing the bulk metal particles with bindermaterial and/or incorporating binder material during the preparation ofthe bulk metal particles leads to bulk catalyst compositions ofparticularly high mechanical strength, in particular if the medianparticle size of the bulk metal particles is in the range of at leastabout 0.5 μm, more preferably at least about 1 μm, most preferably atleast about 2 μm, but preferably not more than about 5000 μm, morepreferably not more than about 1000 μm, even more preferably not morethan about 500 μm, and most preferably not more than about 150 μm. Evenmore preferably, the median particle diameter lies in the range of about1 to about 150 μm and most preferably in the range of about 2 to about150 μm.

The compositing of the bulk metal particles with the material results inbulk metal particles embedded in this material or vice versa. Normally,the morphology of the bulk metal particles is essentially maintained inthe resulting bulk catalyst composition.

As stated above, the material may be selected from the group consistingof binder materials, binder precursor materials, conventionalhydroprocessing catalysts, cracking compounds, phosphorus-containingcompounds, boron-containing compounds, silicon-containing compounds,fluorine-containing compounds, additional transition metals, rare earthmetals or mixtures thereof, a binder material, a conventionalhydroprocessing catalyst, a cracking compound, or mixtures thereof.These materials will be described in more detail below.

The binder materials to be applied may be any materials conventionallyapplied as binders in hydroprocessing catalysts. Examples are silica,silica-alumina, such as conventional silica-alumina, silica-coatedalumina and alumina-coated silica, alumina such as (pseudo) boehmite, orgibbsite, titania, titania-coated alumina, zirconia, hydrotalcite, ormixtures thereof. Preferred binders are silica, silica-alumina, alumina,titania, titania-coated alumina, zirconia, bentonite, or mixturesthereof. These binders may be applied as such or after peptization.

It is also possible to use precursors of these binders which during theprocess of the invention are converted into any of the above-describedbinders. Suitable precursors are, e.g., alkali metal aluminates (toobtain an alumina binder), water glass (to obtain a silica binder), amixture of alkali metal aluminates and water glass (to obtain asilica-alumina binder), aluminium chlorohydrol, aluminium sulfate,aluminium nitrate, aluminium chloride, or mixtures thereof.

If desired, the binder material may be composited with a Group VIBmetal-containing compound and/or a Group VIII non-noble metal-containingcompound, prior to being composited with the bulk metal particles and/orprior to being added during the preparation thereof. Compositing thebinder material with any of these metal-containing compounds may becarried out by impregnation of the binder with these materials. Suitableimpregnation techniques are known to the person skilled in the art. Ifthe binder needs to be peptized, it is also possible to carry out thepeptization in the presence of Group VIB and/or Group VIII non-noblemetal containing compounds.

If alumina is used as binder, the surface area of the alumina generallylies in the range of about 50 to about 600 m²/g and preferably about 100to about 450 m²/g, as measured by the B.E.T. method. The pore volume ofthe alumina preferably is in the range of about 0.1 to about 1.5 ml/g,as measured by nitrogen adsorption. Before the characterization of thealumina, it is thermally treated at 600° C. for 1 hour.

Generally, the binder material to be added in the process of theinvention has less catalytic activity than the bulk metal particles orno catalytic activity at all. Consequently, by adding a binder material,the activity of the bulk catalyst composition may be reduced.Furthermore, the addition of binder material leads to a considerableincrease in the mechanical strength of the final bulk catalystcomposition. Therefore, the amount of binder material to be added in theprocess of the invention generally depends on the desired activityand/or desired mechanical strength of the final bulk catalystcomposition. Binder amounts from 0 to about 95 wt. % of the totalcomposition can be suitable, depending on the envisaged catalyticapplication. However, to take advantage of the resulting unusually highactivity of the bulk metal particles of the present invention, thebinder amounts to be added generally are in the range of about 1 toabout 75 wt. % of the total composition, preferably about 1 to about 50wt. %, more preferably about 1 to about 30 wt. %, even more preferablyabout 3 to about 20 wt. %, and most preferably about 4 to about 12 wt %.

The bulk metal particles of the present invention may also be combinedwith conventional hydroprocessing catalysts include knownhydro-desulfurization, hydrodenitrogenation, or hydrocracking catalysts.These catalysts can be added in the used, regenerated, fresh, orsulfided state. If desired, the conventional hydroprocessing catalystmay be milled or treated in any other conventional way before beingapplied in the process of the invention.

The bulk metal particles of the present invention may also be combinedwith cracking components. A cracking compound according to the presentinvention is any conventional cracking compound such as cationic clays,anionic clays, crystalline cracking compounds such as zeolites, e.g.ZSM-5, (ultra-stable) zeolite Y, zeolite X, ALPOs, SAPOs, MCM-41,amorphous cracking compounds such as silica-alumina, or mixturesthereof. It will be clear that some materials may act as binder andcracking compound at the same time. For instance, silica-alumina mayhave a cracking and a binding function at the same time.

If desired, the cracking compound may be composited with a Group VIBmetal and/or a Group VIII non-noble metal prior to being composited withthe bulk metal particles. Compositing the cracking compound with any ofthese metals may take the form of impregnation of the cracking compoundwith these materials.

Generally, it depends on the envisaged catalytic application of thefinal bulk catalyst composition which of the above-described crackingcompounds, if any, is added. A crystalline cracking compound ispreferably added if the resulting composition is to be applied inhydrocracking. Other cracking compounds such as silica-alumina orcationic clays are preferably added if the final bulk catalystcomposition is to be used in hydrotreating applications or mildhydrocracking. The amount of cracking material which is added depends onthe desired activity of the final composition and the applicationenvisaged, and thus may vary from 0 to about 90 wt. %, based on thetotal weight of the bulk catalyst composition.

Phosphorus-containing compounds that may be combined with the bulk metalparticles include ammonium phosphate, phosphoric acid or organicphosphorus-containing compounds. Phosphorus-containing compounds can beadded prior to the shaping step and/or subsequent to the shaping step.If the binder material needs to be peptized, phosphorus-containingcompounds can also be used for peptization. For instance, an aluminabinder can be peptized by being contacted with phosphoric acid or with amixture of phosphoric acid and nitric acid.

Boron-containing compounds that may be combined with the bulk metalparticles include boric acid or heteropoly compounds of boron withmolybdenum and/or tungsten. A fluorine-containing compound that maytypically be used is ammonium fluoride. Typical silicon-containingcompounds are water glass, silica gel, tetraethylorthosilicate orheteropoly compounds of silicon with molybdenum and/or tungsten.Further, compounds such as fluorosilicic acid, fluoroboric acid,difluorophosphoric acid or hexafluorophosphoric acid may be applied if acombination of F with Si, B and P, respectively, is desired.

Suitable additional transition metals are, e.g., rhenium, manganese,ruthenium, rhodium, iridium, chromium, vanadium, iron, platinum,palladium, titanium, zirconium, niobium, cobalt, nickel, molybdenum, ortungsten. These metals can be added at any stage of the process of thepresent invention prior to the shaping step. Apart from adding thesemetals during the process of the invention, it is also possible tocomposite the final bulk catalyst composition therewith. Thus it ispossible to impregnate the final bulk catalyst composition with animpregnation solution comprising any of these metals.

Process Step (ii)

The bulk metal particles optionally comprising any of the above(further) materials can be subjected to spray-drying, (flash) drying,milling, kneading, slurry-mixing, dry or wet mixing, or combinationsthereof, with a combination of wet mixing and kneading or slurry mixingand spray-drying being preferred.

These techniques can be applied either before or after any of the above(further) materials are added (if at all), after solid-liquidseparation, before or after a thermal treatment, and subsequent tore-wetting.

Preferably, the bulk metal particles are both composited with any of theabove materials and subjected to any of the above techniques. It isbelieved that by applying any of the above-described techniques ofspray-drying, (flash) drying, milling, kneading, slurry-mixing, dry orwet mixing, or combinations thereof, the degree of mixing between thebulk metal particles and any of the above materials is improved. Thisapplies to cases where the material is added before as well as after theapplication of any of the above-described methods. However, it isgenerally preferred to add the material prior to step (ii). If thematerial is added subsequent to step (ii), the resulting compositionpreferably is thoroughly mixed by any conventional technique prior toany further process steps such as shaping. An advantage of spray-dryingis that no waste water streams are obtained when this technique isapplied.

Spray-drying typically is carried out at an outlet temperature in therange of about 100° to about 200° C. and preferably about 120° to about180° C.

Dry mixing means mixing the bulk metal particles in the dry state withany of the above materials in the dry state. Wet mixing generallycomprises mixing the wet filter cake comprising the bulk metal particlesand optionally any of the above materials as powders or wet filter caketo form a homogenous paste thereof.

Process Step (iii)

If so desired, the bulk catalyst optionally comprising any of the above(further) materials may be shaped optionally after step (ii) having beenapplied. Shaping comprises extrusion, pelletizing, beading and/orspray-drying. It must be noted that if the bulk catalyst composition isto be applied in slurry-type reactors, fluidized beds, moving beds, orexpanded beds, generally spray-drying or beading is applied. For fixedbed or ebullating bed applications, generally the bulk catalystcomposition is extruded, pelletized and/or beaded. In the latter case,at any stage prior to or during the shaping step, any additives whichare conventionally used to facilitate shaping can be added. Theseadditives may comprise aluminium stearate, surfactants, graphite,starch, methyl cellulose, bentonite, polyethylene glycols, polyethyleneoxides, or mixtures thereof. Further, when alumina is used as binder, itmay be desirable to add acids such as nitric acid prior to the shapingstep to peptize the alumina and to increase the mechanical strength ofthe extrudates.

If the shaping comprises extrusion, beading and/or spray-drying, it ispreferred that the shaping step is carried out in the presence of aliquid, such as water. Preferably, for extrusion and/or beading, theamount of liquid in the shaping mixture, expressed as LOI, is in therange of about 20 to about 80%.

If so desired, coaxial extrusion of any of the above materials with thebulk metal particles, optionally comprising any of the above materials,may be applied. More in particular, two mixtures can be co-extruded, inwhich case the bulk metal particles optionally comprising any of theabove materials are present in the inner extrusion medium while any ofthe above materials without the bulk metal particles is present in theouter extrusion medium or vice versa.

Process Step (iv)

After an optional drying step, preferably above about 100° C., theresulting shaped bulk catalyst composition may be thermally treated ifdesired. A thermal treatment, however, is not essential to the processof the invention. A “thermal treatment” according to the presentinvention refers to a treatment performed at a temperature of, e.g.,from about 100° to about 600° C., preferably from about 200° to about550° C., more preferably about 250° C. to about 450° C., for a timevarying from about 0.5 to about 48 hours in an inert gas such asnitrogen, or in an oxygen-containing gas, such as air or pure oxygen.The thermal treatment can be carried out in the presence of water steam.

In all the above process steps the amount of liquid must be controlled.Where, prior to subjecting the bulk catalyst composition tospray-drying, the amount of liquid is too low, additional liquid must beadded. Conversely where, prior to extrusion of the bulk catalystcomposition, the amount of liquid is too high, the amount of liquid mustbe reduced using solid-liquid separation techniques such as filtration,decantation, or evaporation and, if necessary, the resulting materialcan be dried and subsequently re-wetted to a certain extent. For all theabove process steps, it is within the scope of the skilled person tocontrol the amount of liquid appropriately.

Process Step (v)

The process of the present invention may further comprise a sulfidationstep. Sulfidation generally is carried out by contacting the bulk metalparticles, directly after their preparation or after any one of processsteps (i)-(iv), with a sulfur-containing compound such as elementarysulfur, hydrogen sulfide, dimethyl disulfide (DMDS), or organic orinorganic polysulfides. The sulfidation step can be carried out in theliquid and the gaseous phase. The sulfidation can be carried outsubsequent to the preparation of the bulk catalyst composition but priorto step (i) and/or subsequent to step (i) but prior to step (ii) and/orsubsequent to step (ii) but prior to step (iii) and/or subsequent tostep (iii) but prior to step (iv) and/or subsequent to step (iv). It ispreferred that the sulfidation is not carried out prior to any processstep by which the obtained metal sulfides revert to their oxides. Suchprocess steps are, e.g., a thermal treatment or spray-drying or anyother high-temperature treatment if carried out under anoxygen-containing atmosphere. Consequently, if the bulk catalystcomposition is subjected to spray-drying and/or any alternativetechnique or to a thermal treatment under an oxygen-containingatmosphere, the sulfidation preferably is carried out subsequent to theapplication of any of these methods. Of course, if these methods areapplied under an inert atmosphere, sulfidation can also be carried outprior to these methods.

If the bulk catalyst composition is used in fixed bed processes, thesulfidation preferably is carried out subsequent to the shaping stepand, if applied, subsequent to the last thermal treatment in anoxidizing atmosphere.

The sulfidation can generally be carried out in situ and/or ex situ.Preferably, the sulfidation is carried out ex situ, i.e. the sulfidationis carried out in a separate reactor prior to the sulfided bulk catalystcomposition being loaded into the hydroprocessing unit. Furthermore, itis preferred that the bulk catalyst composition is sulfided both ex situand in situ.

A preferred process of the present invention comprises the followingsuccessive process steps of preparing the bulk metal particles asdescribed above, slurry mixing the obtained bulk metal particles with,e.g., a binder, spray drying the resulting composition, rewetting,kneading, extrusion, drying, calcining and sulfiding. Another preferredprocess embodiment comprises the following successive steps of preparingthe bulk metal particles as described above, isolating the particles viafiltration, wet mixing the filter cake with a material, such as abinder, kneading, extrusion, drying, calcining and sulfiding.

Bulk Catalyst Composition of the Invention

The invention further pertains to a bulk catalyst composition obtainableby the above-described process. Preferably, the invention pertains to abulk catalyst composition obtainable by process step (A) and optionallyone or more of process steps B (i)-(v) described above.

In a preferred embodiment, the invention pertains to a bulk catalystcomposition obtainable by the above-described process wherein themorphology of the metal compound(s) which are at least partly in thesolid state during the process is retained to some extent in the bulkcatalyst composition. This retention of morphology is described indetail under the heading “Process of the present invention.”

(a) Oxidic Bulk Catalyst Composition

Furthermore, the invention pertains to a bulk catalyst compositioncomprising bulk metal particles which comprise at least one Group VIIInon-noble metal and at least one Group VIB metal, wherein the metals arepresent in the bulk catalyst composition in their oxidic state, andwherein the characteristic full width at half maximum does not exceed2.5° when the Group VIB metal is molybdenum, tungsten, a combination ofmolybdenum and tungsten or a combination of molybdenum, tungsten andchromium, or does not exceed 4.0° when the Group VIB metal is acombination of molybdenum and chromium or a combination of tungsten andchromium.

As described under the heading “characterization methods”, thecharacteristic full width at half maximum is determined on the basis ofthe peak located at 2θ=53.9° (±1.0°) (when the Group VIB metal ismolybdenum, tungsten, a combination of molybdenum and tungsten or acombination of molybdenum, tungsten and chromium) or at 2θ=63.5° (±0.6°)(when the Group VIB metal is a combination of molybdenum and chromium ora combination of tungsten and chromium).

Preferably, the characteristic full width at half maximum does notexceed 2.2°, more preferably 2.0°, still more preferably 1.8°, and mostpreferably, it does not exceed 1.6° when the Group VIB metal ismolybdenum, tungsten, a combination of molybdenum and tungsten or acombination of molybdenum, tungsten and chromium, or it does not exceed3.5°, more preferably 3.0°, still more preferably 2.5°, and mostpreferably 2.0°, when the Group VIB metal is a combination of molybdenumand chromium or a combination of tungsten and chromium).

Preferably, the X-ray diffraction pattern shows peaks at the positions2θ=35.9° (±0.6°), 38.7° (±0.6°), 40.8° (±0.7°), 53.9 (±1.0°) and 64.5(±1.2°) when the Group VIB metals include tungsten. A typical X-raydiffraction pattern for a metal oxide catalyst of the inventioncomprising tungsten is shown in FIG. 1.

From the characteristic full width at half maximum of the oxidic bulkcatalyst compositions of the present invention, it can be deduced thatthe microstructure of the catalyst of the present invention differs fromthat of corresponding catalysts prepared via co-precipitation asdescribed in International Patent Application Publication No. WO99/03578 or U.S. Pat. No. 3,678,124.

The X-ray diffraction pattern of the bulk metal particles preferablydoes not contain any peaks characteristic of the metal compounds to bereacted. Of course, if desired, it is also possible to choose theamounts of metal compounds in such a way as to obtain bulk metalparticles characterized by an X-ray diffraction pattern still comprisingone or more peaks characteristic to at least one of these metalcompounds. If, e.g., a high amount of the metal compound which is atleast partly in the solid state during the process of the invention isadded, or if this metal compound is added in the form of largecrystalline particles, small amounts of this metal compound may betraced in the X-ray diffraction pattern of the resulting bulk metalparticles.

The molar ratio of Group VIB to Group VIII non-noble metals generallyranges from about 10:1 to about 1:10 and preferably from about 3:1 toabout 1:3. In the case of a core-shell structured particle, these ratiosof course apply to the metals contained in the shell. The ratio of thedifferent Group VIB metals to one another generally is not critical. Thesame holds when more than one Group VIII non-noble metal is applied. Incases where molybdenum and tungsten are present as Group VIB metals, themolybenum:tungsten ratio preferably lies in the range of about 9:1 toabout 1:19, more preferably about 3:1 to about 1:9, most preferablyabout 3:1 to about 1:6.

The bulk metal particles may comprise only one Group VIII non-noblemetal and only one Group VIB metal compound. In this embodiment,preferred bimetallic combinations comprise nickel-tungsten,cobalt-tungsten, nickel-molybdenum and cobalt-molybdenum, morepreferably, nickel-tungsten.

The bulk metal particles may however equally comprise at least one GroupVIII non-noble metal compound and at least two Group VIB metalcompounds. Suitable Group VIB metals include chromium, molybdenum,tungsten, or mixtures thereof, with a combination of molybdenum andtungsten being most preferred. Suitable Group VIII non-noble metalsinclude iron, cobalt, nickel, or mixtures thereof, preferably nickeland/or cobalt. Preferably, a combination of metals comprising nickel,molybdenum, and tungsten or nickel, cobalt, molybdenum, and tungsten, orcobalt, molybdenum, and tungsten is contained in the bulk metalparticles of the invention.

Preferably, the oxidic bulk metal particles comprised in these bulkcatalyst compositions have a B.E.T. surface area of at least about 10m²/g, more preferably of at least about 50 m²/g, and most preferably ofat least about 80 m²/g, as measured via the B.E.T. method.

If during the preparation of the bulk metal particles none of the above(further) materials, such as a binder material, a cracking compound or aconventional hydroprocessing catalyst, have been added, the bulkcatalyst particles will comprise about 85 to about 99.5 wt. % of GroupVIB and Group VIII non-noble metals. If any of the above materials havebeen added during the preparation of the bulk metal particles, they willstill preferably comprise greater than about 50 wt. %, and morepreferably greater than about 70 wt. % of the Group VIB and Group VIIInon-noble metals, calculated as oxides and based on the total weight ofthe bulk metal particles, the balance being any of the above-mentioned(further) materials. The amount of Group VIB and Group VIII non-noblemetals can be determined via TEM-EDX, SEM-EDX, AAS, ICP and/orappropriate combinations of these methodologies. TEM and SEM-EDX is usedto determine concentrations on nanometer or micrometer scale; AAS andICP are bulk methods.

The median pore diameter (50% of the pore volume is below said diameter,the other 50% above it) of the oxidic bulk metal particles preferably isabout 1 to about 25 nm, more preferably about 2 to about 15 nm and mostpreferably about 5 to about 15 nm (determined by N₂ adsorption).

The total pore volume of the oxidic bulk metal particles preferably isat least about 0.05 ml/g, more preferably at least about 0.1 ml/g, andmost preferably greater than about 0.2 ml/g as determined by N₂adsorption.

It is desired that the pore size distribution of the bulk metalparticles is similar to that of conventional hydroprocessing catalysts.More particularly, the bulk metal particles preferably have a medianpore diameter of about 3 to about 25 nm, as determined by nitrogenadsorption, a pore volume of about 0.05 to about 5 ml/g, more preferablyof about 0.05 to about 4 ml/g, still more preferably of about 0.05 toabout 3 ml/g, and most preferably of about 0.1 to about 2 ml/g, asdetermined by nitrogen adsorption.

Furthermore, these bulk metal particles preferably have a medianparticle size in the range of at least about 0.5 μm, more preferably atleast about 1 μm, most preferably at least about 2 μm, but preferablynot more than about 5000 μm, more preferably not more than about 1000μm, even more preferably not more than about 500 μm, and most preferablynot more than about 150 μm. Even more preferably, the median particlediameter lies in the range of about 1 to about 150 μm and mostpreferably in the range of about 2 to about 150 μm.

As has been mentioned above, if so desired, it is possible to preparecore-shell structured bulk metal particles using the process of theinvention. In these particles, at least one of the metals isanisotropically distributed in the bulk metal particles. Theconcentration of a metal, the metal compound of which is at least partlyin the solid state during the process of the invention, generally ishigher in the inner part, i.e., the core of the final bulk metalparticles, than in the outer part, i.e. the shell of the final bulkmetal particles. Generally, the concentration of this metal in the shellof the final bulk metal particles is at most about 95% and in most casesat most about 90% of the concentration of this metal in the core of thefinal bulk metal particles. Further, it has been found that the metal ofa metal compound which is applied in the solute state during the processof the invention is also anisotropically distributed in the final bulkmetal particles. More particularly, the concentration of this metal inthe core of the final bulk metal particles generally is lower than theconcentration of this metal in the shell. Still more particularly, theconcentration of this metal in the core of the final bulk metalparticles is at most about 80% and frequently at most about 70% andoften at most about 60% of the concentration of this metal in the shell.It must be noted that the above-described anisotropic metaldistributions, if any, can be found in the bulk catalyst composition ofthe invention irrespective of whether the bulk catalyst composition hasbeen thermally treated and/or sulfided. In the above cases, the shellgenerally has a thickness of about 10 to about 1,000 nm.

Though the above anisotropic metal distribution can be formed/obtainedduring the process of the invention, the Group VIB and Group VIIInon-noble metals generally are homogeneously distributed in the bulkmetal particles. This embodiment generally is preferred.

Preferably, the bulk catalyst composition additionally comprises asuitable binder material. Suitable binder materials preferably are thosedescribed above. The particles generally are embedded in the bindermaterial, which functions as a glue to hold the particles together.Preferably, the particles are homogeneously distributed within thebinder. The presence of the binder generally leads to an increasedmechanical strength of the final bulk catalyst composition. Generally,the bulk catalyst composition of the invention has a mechanicalstrength, expressed as side crush strength, of at least about 1 lbs/mmand preferably of at least about 3 lbs/mm (measured on extrudates with adiameter of 1-2 mm).

The amount of binder depends inter alia on the desired activity of thebulk catalyst composition. Binder amounts from 0 to about 95 wt. % ofthe total composition can be suitable, depending on the envisagedcatalytic application. However, to take advantage of the unusually highactivity of the composition of the present invention, the binder amountsgenerally are in the range of 0 to about 75 wt. % of the totalcomposition, preferably 0 to about 50 wt. %, more preferably 0 to about30 wt. %.

If desired, the bulk catalyst composition may comprise a suitablecracking compound. Suitable cracking compounds preferably are thosedescribed above. The amount of cracking compound preferably is in therange of 0 to about 90 wt. %, based on the total weight of the bulkcatalyst composition.

Moreover, the bulk catalyst composition may comprise conventionalhydroprocessing catalysts. The conventional hydroprocessing catalystgenerally comprises any of the above-described binder materials andcracking compounds. The hydrogenation metals of the conventionalhydroprocessing catalyst generally comprise Group VIB and Group VIIInon-noble metals such as combinations of nickel or cobalt withmolybdenum or tungsten. Suitable conventional hydroprocessing catalystsinclude hydrotreating or hydrocracking catalysts. These catalysts can bein the used, regenerated, fresh, or sulfided state.

Furthermore, the bulk catalyst composition may comprise any furthermaterial which is conventionally present in hydroprocessing catalystssuch as phosphorus-containing compounds, boron-containing compounds,silicon-containing compounds, fluorine-containing compounds, additionaltransition metals, rare earth metals, or mixtures thereof. Details inrespect of these further materials are given above. The transition orrare earth metals generally are present in the oxidic form when the bulkcatalyst composition has been thermally treated in an oxidizingatmosphere and/or in the sulfided form when the bulk catalystcomposition has been sulfided.

To obtain bulk catalyst compositions with high mechanical strength, itmay be desirable for the bulk catalyst composition of the invention tohave a low macroporosity. Preferably, less than about 30% of the porevolume of the bulk catalyst composition is in pores with a diameterhigher than about 100 nm (determined by mercury intrusion, contactangle: 130°), more preferably less than about 20%.

The oxidic bulk catalyst composition of the present invention generallycomprises about 10 to about 100 wt. %, preferably about 25 to about 100wt. %, more preferably about 45 to about 100 wt. % and most preferablyabout 65 to about 100 wt. % of Group VIB and Group VIII non-noblemetals, based on the total weight of the bulk catalyst composition,calculated as metal oxides.

It is noted that a catalyst prepared via stepwise impregnation withGroup VIB and Group VIII non-noble metal solutions on an alumina carrieras described in JP 09000929 does not comprise any bulk metal particlesand thus has a morphology which is completely different from that of thepresent invention.

(b) Sulfided Bulk Catalyst Composition

If so desired, the bulk catalyst composition of the present inventioncan be sulfided. Consequently, the present invention further pertains toa bulk catalyst composition comprising sulfidic bulk metal particleswhich comprise at least one Group VIII non-noble metal and at least oneGroup VIB metal and wherein the degree of sulfidation under conditionsof use does not exceed about 90%.

It will be clear that the above sulfided bulk catalyst composition maycomprise any of the above-described (further) materials.

The present invention further pertains to a shaped and sulfided bulkcatalyst composition comprising

-   -   (i) sulfidic bulk metal particles comprising nanoparticles, at        least one Group VIII non-noble metal and at least two Group VIB        metals, wherein the degree of sulfidation under conditions of        use does not exceed about 90% and    -   (ii) a material selected from the group of binder materials,        conventional hydroprocessing catalysts, cracking compounds, or        mixtures thereof.

It is essential that the degree of sulfidation of the sulfidic bulkmetal particles under conditions of use does not exceed about 90%.Preferably, the degree of sulfidation under conditions of use is in therange of about 10 to about 90%, more preferably of about 20 to about90%, and most preferably of about 40 to about 90%. The degree ofsulfidation is determined as described under the heading“characterization methods.”

If conventional sulfidation techniques are applied in the process of thepresent invention, the degree of sulfidation of the sulfidic bulk metalparticles prior to use is essentially identical to the degree ofsulfidation under conditions of use. However, if very specificsulfidation techniques are applied, it might be that the degree ofsulfidation prior to the use of the catalyst is higher than during theuse thereof, as during use part of the sulfides or elemental sulfur isremoved from the catalyst. In this case the degree of sulfidation is theone that results during use of the catalyst and not prior thereto. Theconditions of use are those described below in the chapter “useaccording to the invention.” That the catalyst is “under conditions ofuse” means that it is subjected to these conditions for a time periodlong enough for the catalyst to reach equilibrium with its reactionenvironment.

It is further preferred that the bulk catalyst composition of thepresent invention is essentially free of Group VIII non-noble metaldisulfides. More in particular, the Group VIII non-noble metals arepreferably present as (Group VIII non-noble metal)_(y)S_(x), with x/ybeing in the range of about 0.5 to about 1.5

The shaped and sulfided catalyst particles may have many differentshapes. Suitable shapes include spheres, cylinders, rings, and symmetricor asymmetric polylobes, for instance tri- and quadrulobes. Particlesresulting from extrusion, beading or pilling usually have a diameter inthe range of about 0.2 to about 10 mm, and their length likewise is inthe range of about 0.5 to about 20 mm. Particles resulting fromspray-drying generally have a median particle diameter in the range ofabout 1 μm to about 100 μm.

Details about the binder materials, cracking compounds, conventionalhydro-processing catalysts, and any further materials as well as theamounts thereof are given above. Further, details in respect of theGroup VIII non-noble metals and the Group VIB metals contained in thesulfided bulk catalyst compositions and the amounts thereof are givenabove.

It is noted that the core-shell structure described above for the oxidicbulk catalyst composition is not destroyed by sulfidation, i.e., thesulfided bulk catalyst compositions may also comprise this core-shellstructure.

It is further noted that the sulfided catalysts are at least partlycrystalline materials, i.e., the X-ray diffraction pattern of thesulfided bulk metal particles generally comprises several crystallinepeaks characteristic to the Group VIII non-noble metal and Group VIBmetal sulfides.

As for the oxidic bulk catalyst composition, preferably, less than about30% of the pore volume of the sulfidic bulk catalyst composition is inpores with a diameter higher than about 100 nm (determined by mercuryintrusion, contact angle: 130°), more preferably less than about 20%.

Generally, the median particle diameters of the sulfidic bulk metalparticles are identical to those given above for the oxidic bulk metalparticles.

Use According to the Invention

The bulk catalyst composition according to the invention is particularlyuseful for hydroprocessing hydrocarbon feedstocks. Accordingly, theinvention relates to a process for hydroprocessing a hydrocarbonfeedstock, said process comprising contacting a hydrocarbon feedstockunder hydroprocessing conditions with a catalyst composition comprisingbulk metal particles that comprise at least one Group VIII non-noblemetal, at least one Group VIB metal and nanoparticles.

The catalyst composition according to the invention can be used invirtually all hydroprocessing processes to treat a plurality of feedsunder wide-ranging reaction conditions such as temperatures of from 100to 450° C., hydrogen pressures of from 5 to 1200 bar, preferably below300 bars, liquid hourly space velocities of from 0.05 to 10 h⁻¹ andhydrogen treat gas rates of from about 18 to about 1800 m³/m³ (100 to10,000 SCF/B). The term hydroprocessing used in the context of thisinvention encompasses all processes in which a hydrocarbon feedstock isreacted with hydrogen at the temperatures and pressures noted above, andincluding hydrogenation, hydrodesulfurization, hydrodenitrogenation,hydrodemetallization, hydrodearomatization, hydroisomerization,hydrodewaxing, hydrotreating, hydrofinishing and hydrocracking.

The catalyst composition of the invention is particularly effective forthe removal of nitrogen and sulfur from a hydrocarbon feed. Accordingly,in a preferred embodiment, the catalyst of the invention is used toremove sulfur, nitrogen, or a combination of sulfur and nitrogen, fromhydrocarbon feedstocks. The contacting of the hydrocarbon feedstock withthe catalyst composition occurs in the presence of a hydrogen-containingtreat gas, and the reaction is operated under effective hydroprocessingconditions. The contacting of the hydrocarbon feedstock with thecatalyst composition produces a hydrocarbon product, liquid underatmospheric conditions, that has less nitrogen, sulfur, or both,compared to the feedstock.

The hydrocarbon feedstock is a material comprising hydrogen and carbon.A wide range of petroleum and chemical hydrocarbon feedstocks can behydroprocessed in accordance with the present invention. Hydrocarbonfeedstocks include those obtained or derived from crude petroleum oil,from tar sands, from coal liquefaction, from shale oil and fromhydrocarbon synthesis, such as reduced crudes, hydrocrackates,raffinates, hydrotreated oils, atmospheric and vacuum gas oils, cokergas oils, atmospheric and vacuum resids, deasphalted oils, dewaxed oils,slack waxes, Fischer-Tropsch waxes and mixtures thereof. Suitablefeedstocks range from relatively light distillate fractions up to heavyfeedstocks, such as gas oils, lube oils and resids. Non-limitingexamples of light distillate feedstocks include naphtha (typical boilingrange of from about 25° C. to about 210° C.), diesel (typical boilingrange of from about 150° C. to about 400° C.), kerosene or jet fuel(typical boiling range of from about 150° C. to about 250° C.) and thelike. Non-limiting examples of heavy feedstocks include vacuum (orheavy) gas oils (typical boiling range of from about 315° C. to about610° C.), raffinates, lube oils, cycle oils, waxy oils and the like.Preferred hydrocarbon feedstocks have a boiling range of from about 150°C. to about 650° C., conveniently from about 150° C. to about 450° C.

The catalyst composition of the present invention is particularlyeffective for removing sulfur, nitrogen or a combination of sulfur andnitrogen from hydrocarbon feedstocks. Hydrocarbon feedstocks indeedoften contain nitrogen and sulfur contaminants, often in the form ofsulfur and/or nitrogen-containing organic compounds. The nitrogencontent of the feedstock can be up to about 5000 wppm nitrogen,preferably up to about 2000 wppm nitrogen, more preferably up to 1000wppm nitrogen and most preferably up to 500 wppm nitrogen. Nitrogencontaminants may be basic or non-basic. Examples of basic nitrogencontaminants include quinolines and substituted quinolines, and examplesof non-basic nitrogen species include carbazoles and substitutedcarbazoles. The sulfur content of the feedstock may be from 0.05 wt % to3 wt %, and is typically less than 2 wt %.

In a preferred embodiment, effective hydroprocessing conditions areeffective hydrotreating conditions, that is, conditions effective for atleast one of (i) hydrogenation or (ii) hydrogenolysis. Generally,hydrotreating conditions will result in removing at least a portion ofthe heteroatoms in the feed and in hydrogenating at least a portion ofthe aromatics in the feed. Hydrotreating conditions typically includetemperatures ranging from about 100° C. to about 450° C., preferablyfrom about 200° C. to about 370° C., more preferably from about 230° C.to about 350° C. Typical liquid hourly space velocities (“LHSV”) rangefrom about 0.05 to about 20 hr⁻¹, preferably from about 0.5 to about 5hr⁻¹. Any effective pressure can be utilized, and pressures typicallyrange from about to about 250 bar. Hydrogen (H₂) to oil ratio generallyranges from about 18 to about 1800 m³/m³ (100 to 10000 SCF/B). Processconditions may vary, as is known to those skilled in the art, dependingon the feed boiling range and speciation. Generally, as the boilingpoint of the feed increases, the severity of the conditions will alsoincrease. The following table serves to illustrate typical conditionsfor a range of feeds.

TYPICAL SPACE BOILING PRESS, VELOCITY H₂ GAS RATE FEED RANGE ° C. TEMP.°C. BAR V/V/HR SCF/B Naphtha  25-210 100-370 10-60   0.5-10 100-2,000Diesel 150-400 200-400 15-110 0.5-4 500-6,000 Heavy 315-610 260-43015-170 0.3-2 1000-6,000  Gas Oil Lube Oil 290-550 200-450  6-210 0.2-5 100-10,000 Resid 10-50%>575 340-450  65-1100 0.1-1 2,000-10,000 

The process uses hydrogen or a hydrogen-containing treat gas. Treat gascan comprise substantially pure hydrogen or can be mixtures of othercomponents typically found in refinery hydrogen streams. It is preferredthat the treat gas contain little, more preferably no, hydrogen sulfide.The treat gas purity should be at least about 50% by volume hydrogen,preferably at least about 75% by volume hydrogen, and more preferably atleast about 90% by volume hydrogen. The treat gas can be pure orsubstantially pure hydrogen.

The hydroprocessing occurs in a reaction stage. The reaction stage cancomprise one or more reactors or reaction zones each of which comprisesone or more catalyst beds of the same or different catalyst. At leastone bed will contain the catalyst composition of the invention. Althoughother types of catalyst beds/reactors can be used, fixed beds arepreferred. Such other types of catalyst beds include fluidized beds,ebullating beds, slurry beds, and moving beds. Interstage cooling orheating between reactors, reaction zones, or between catalyst beds inthe same reactor, can be employed. A portion of the heat generatedduring hydroprocessing can be recovered. Where this heat recovery optionis not available, conventional cooling may be performed through coolingutilities such as cooling water or air, or through use of a hydrogenquench stream. In this manner, optimum reaction temperatures can be moreeasily maintained.

Characterization Methods

The methods described below represent those characterization methodsdeemed most appropriate for this invention. However, the skilled personwould be aware of other techniques, such as Raman or Infraredspectroscopy that could equally be employed in characterization ofproducts.

Side Crush Strength Determination

First, the length of, e.g., an extrudate particle was measured, and thenthe extrudate particle was subjected to compressive loading (25 lbs in8.6 sec.) by a movable piston. The force required to crush the particlewas measured. The procedure was repeated with at least 40 extrudateparticles and the average was calculated as force (lbs) per unit length(mm). The method preferably was applied to shaped particles with alength not exceeding 7 mm.

2. Pore Volume via N₂ Adsorption

The N₂ adsorption measurement was carried out as described in the Ph.D.dissertation of J. C. P. Broekhoff (Delft University of Technology1969), the disclosure of which is hereby incorporated by reference.

3. Amount of Added Solid Metal Compounds

Qualitative determination: The presence of solid metal compounds duringthe process of the invention can easily be detected by visual inspectionat least if the metal compounds are present in the form of particleswith a diameter larger than the wavelength of visible light. Of course,methods such as quasi-elastic light scattering (QELS) or near-forwardscattering, which are known to the skilled person, can also be used toverify that at no point in time during the process of the invention allmetals will be in the solute state.

Quantitative determination: if the metal compounds which are added atleast partly in the solid state are added as suspension(s), the amountof solid metal compounds added during the process of the invention canbe determined by filtration of the suspension(s) to be added under theconditions which are applied during the addition (temperature, pH,pressure, amount of liquid), in such a way that all solid materialcontained in the suspension(s) is collected as solid filter cake. Fromthe weight of the solid and dried filter cake, the weight of the solidmetal compounds can be determined by standard techniques. Of course, ifapart from solid metal compounds further solid compounds, such as asolid binder, are present in the filter cake, the weight of this solidand dried binder must be subtracted from the weight of the solid anddried filter cake.

The amount of solid metal compounds in the filter cake can also bedetermined by standard techniques such as atomic absorption spectroscopy(AAS), XRF, wet chemical analysis, or ICP.

If the metal compounds which are added at least partly in the solidstate are added in the wetted or dry state, a filtration generally isnot possible. In this case, the weight of the solid metal compounds isconsidered equal to the weight of the corresponding initially employedmetal compounds, on a dry basis. The total weight of all metal compoundsis the amount of all metal compounds initially employed, on a dry basis,calculated as metal oxides.

4. Characteristic Full Width at Half Maximum

The characteristic full width at half maximum of the oxidic catalystswas determined on the basis of the X-ray diffraction pattern of thecatalysts using a linear background:

-   -   (a) if the Group VIB metals are molybdenum and tungsten: the        characteristic full width at half maximum is the full width at        half maximum (in terms of 20) of the peak at 2θ=53.6° (±0.7°)    -   (b) if the Group VIB metals are molybdenum and chromium: the        characteristic full width at half maximum is the full width at        half maximum (in terms of 2θ) of the peak at 2θ=63.5° (±0.6°)    -   (c) if the Group VIB metals are tungsten and chromium: the        characteristic full width at half maximum is the full width at        half maximum (in terms of 2θ) of the peak at 2θ=53.6° (±0.7°)    -   (d) if the Group VIB metals are molybdenum, tungsten, and        chromium: the characteristic full width at half maximum is the        full width at half maximum (in terms of 2θ) of the peak at)        2θ=53.6° (±0.7°).

For the determination of the X-ray diffraction pattern, a standardpowder diffractometer (e.g., Philips PW1050) equipped with a graphitemonochromator can be used. The measurement conditions can be chosen asfollows:

-   -   X-ray generator settings: 40 kV and 40 mA    -   wavelength: 1.5418 angstroms    -   divergence and anti-scatter slits: 1°    -   detector slit: 0.2 mm,    -   step size: 0.04 (°2Θ)    -   time/step: 20 seconds.

5. Degree of Sulfidation

Any sulfur contained in the sulfidic bulk catalyst composition wasoxidized in an oxygen flow by heating in an induction oven. Theresulting sulfur dioxide was analyzed using an infrared cell with adetection system based on the IR characteristics of the sulfur dioxide.To obtain the amount of sulfur the signals relating to sulfur dioxideare compared to those obtained on calibration with well-known standards.The degree of sulfidation is then calculated as the ratio between theamount of sulfur contained in the sulfidic bulk metal particles and theamount of sulfur that would be present in the bulk metal particles ifall Group VIB and Group VIII non-noble metals were present in the formof their disulfides.

It will be clear to the skilled person that the catalyst, the degree ofsulfidation of which is to be measured, is to be handled under an inertatmosphere prior to the determination of the degree of sulfidation.

6. Dimension of the Nanoparticles

The dimension of the dispersed nanoparticles can be determined bytransmission electron microscopy (TEM) (for example, after carefulevaporation of a suspension of dispersed particles or, as the claynanoparticles have different morphology than the bulk catalyst, by TEManalysis of bulk catalyst particles), or by light scattering methods (f.ex. in the slurry). Although an accurate and absolute value for thedimension is difficult to establish, it is for the purposes of theinvention sufficient to determine that a sufficiently large part,preferably at least about 50%, has a size below one micrometer. Thisassessment can be done by taking a TEM picture as is known by the personskilled in the art and assessing on a representative picture, preferablycovering an area of at least about 500 by about 500 nanometer, whetherthere are a substantial number of particles having a size less thanabout 500 nanometer.

The invention will be further illustrated by the following Examples.

Example E1 Ni1Mo0.5W0.5+3 w % Laponite

20.3 g of laponite (LOI=11.2%, Laponite RD available from RockwoodAdditives Limited) was suspended in water in a separate stirred vesselfor approximately one hour. According to the supplier specification,disc-like platelets of about 0.92 nm thickness and having a lateraldimension of about 25 nm and a surface area of over 900 m²·g⁻¹ should beobtained after complete delamination. The particle length and stackingwas verified using TEM. Most of the clay particles indeed consisted of asingle layer about 25 nm long. However, a small portion of the clayparticles was not fully delaminated, i.e. the particles were longer (upto 60 nm) and consisted of multiple layers (up to 5 layers.)

Separately, 1211 g of nickel hydroxy carbonate paste (10.7 wt. % Ni:2.21 mol Ni) was suspended in water and the mixture was stirred untilthe slurry became homogeneous. Then 161 g of MoO₃ (99.1% MoO₃, 1.1 molMo) and 277 g H₂WO₄ (92.7 wt % WO₃, 1.03 mol W) were added to the nickelslurry and the mixture was stirred until the slurry became homogeneous.Then the laponite suspension was added and the mixture was stirred untilthe slurry became homogeneous. The reaction was carried out in an openvessel. The reaction mixture was stirred during the entire process, i.e.when combining the raw materials and when reacting them. The reactionwas carried out by increasing the temperature to 95° C. and maintainingthe mixture at that temperature for 24 hours. The pH of the reactionmixture was 5.2 at the start of the reaction time and 5.0 at the end ofthe reaction time.

The slurry was then allowed to cool down and was then filtered. Theresulting filter cake was combined with surfactant and 15.3 gr ofattapulgite (LOI=20.5%), a needle-like clay mineral composed ofmagnesium-aluminum silicate having a lateral dimension above 1micrometer in a kneader. Furthermore, 27.6 g of microgranular SiO₂(LOI=11.8 wt. %, surface area of about 190 m²/g, median particlediameter of 22 micrometer) was added to the cake. Depending on the watercontent of the filter cake, the water content of the extrusion mix wasadjusted (by adding water or by evaporating water) to obtain anextrudable mix. The mix was then extruded, dried in air at 120° C.overnight and calcined at 340° C. for ½ hour. The amount of laponite(relative to the total amount of metal oxides+laponite) was 3.0 wt %.The amount of laponite in the end product (=final calcined catalystincluding also ca. 1.9 wt. % attapulgite and ca. 3.8 wt. % silica) was2.8 wt. %. This catalyst was then sulfided and tested as described belowin Test Procedures 1 and 2.

Comparative Experiment C1 Ni1Mo0.5W0.5

In this experiment, Example E1 was repeated without the addition of thelaponite suspension. This catalyst was then sulfided and tested asdescribed below in Test Procedures 1 and 2.

Testing E1 and C1 by Test Procedures 1 and 2

The catalysts prepared in examples E1 and C1 were tested in TestProcedure 1 described below in the hydrotreatment of a Vacuum Gas Oil(VGO) feedstock using 4 different test conditions (TC1.1 to TC1.4,respectively) and in Test Procedure 2 in the hydrotreatement of UltraLow Sulfur Diesel (ULSD) feedstock using in 2 different test conditions(TC2.1 and TC2.2, respectively). The test conditions and the testresults are given in Table 3. For each test procedure the residualsulfur level (S in ppm) and nitrogen (N in ppm) is given with theactivity (relative volume activity RVA) for sulfur removal (HDS) andnitrogen removal (HDN). For each test condition, the activity of thecatalyst of the comparative experiment was set at 100% and the activityof the catalysts according to the invention was expressed in percentagerelative to the comparative catalyst. CBD is the compacted bulk densityof the catalyst. Details of the test procedure are described in moredetail below.

Test Procedure 1 VGO Testing

The catalysts were tested in an upflow tubular reactor. Each reactortube contained 50 ml of catalyst mixed with an equal amount of SiCparticles and sandwiched between layers of SiC particles. Before testingthe catalysts were presulfided via liquid phase presulfiding, using thefeed described below in Table 1 which had been spiked with dimethyldisulfide to a total sulfur content of 3.7 wt. % at temperature of 320°C., a pressure of 40 bar, a hydrogen to oil ratio (N1/1) of 300 and at aliquid hourly space volume (LHSV) (1/h) of 1.76. The presulfidedcatalysts were then tested in the hydrotreating of a VGO feedstockhaving the properties shown in Table 1.

TABLE 1 VGO feed Feed Density at 15° C. (g/ml) 0.9207 Density at 50° C.(g/ml) 0.8964 Hydrogen Content (% wt.) 12.2 Sulfur Content (% wt.)1.6297 Nitrogen Content 1714 (ppmwt.) Pour Point (° C.) 46 Viscosity at50° C. (mm²/s) 25.91 Total Aromatics 46.1 ASTM Distillation IBP (° C.)268.2 V05 (° C.) 340.4 V10 (° C.) 370.0 V20 (° C.) 407.6 V30 (° C.)433.6 V40 (° C.) 455.7 V50 (° C.) 475.9 V60 (° C.) 495.0 V70 (° C.)514.4 V80 (° C.) 536.7 V90 (° C.) 563.6 V95 (° C.) 578.7 FBP (° C.)611.4

The results of the VGO test for the catalysts of examples E1 and C1 areshown in Table 3.

Test Procedure 2 ULSD Testing

The catalysts were tested in the same way as in Test Procedure 1, exceptthe amount of catalyst was 10 ml instead of 50 ml, the liquid hourlyspace volume (LHSV) (1/h) was 3.00 instead of 1.76 and the feedstockspiked with dimethyl disulfide was the ultra low sulfur feed of Table 2.The presulfided catalysts were then tested in the hydrotreating of adiesel feedstock having the properties shown in Table 2:

TABLE 2 ULTRA LOW SULFUR DIESEL FEED S (wt. %) 1.2 N (ppmwt) 102 Totalaromatics (wt. %) 28.3 Polynuclear aromatic (PNA) (wt. %) 11.8Mono-aromatics (wt. %) 16.5 Di-aromatics (wt. %) 11.0 Di+-aromatics (wt.%) 0.8 Simulated distillation ASTM-D 86 Initial boiling point 178.4° C. 5 vol. % 211.1° C. 10 vol. % 224.0° C. 30 vol. % 261.4° C. 50 vol. %283.8° C. 70 vol. % 309.3° C. 90 vol. % 347.8° C. Final boiling point372.0° C.

The results of the VGO test for the catalysts of examples E1 and C1 areshown in Table 3.

TABLE 3 H2/oil LHSV CBD S N RVA RVA sample Composition test T (° C.) P(bar) (Nl/l) (1/h) loaded ppm ppm HDS HDN VGO E1.1 Ni1.5Mo0.5W0.5, 3 wt% Lap TC1.1 360 120 1000 1.25 1.22 44.6 155 116 121 C1.1 Ni1.5Mo0.5W0.5TC1.1 360 120 1000 1.25 1.12 53.7 232 100 100 E1.2 Ni1.5Mo0.5W0.5, 3 wt% Lap TC1.2 370 120 1000 1.25 1.22 9.1 35 130 115 C1.2 Ni1.5Mo0.5W0.5TC1.2 370 120 1000 1.25 1.12 12.9 57 100 100 E1.3 Ni1.5Mo0.5W0.5, 3 wt %Lap TC1.3 370 120 1000 0.9 1.22 1.9 cnbd 115 cnbd C1.3 Ni1.5Mo0.5W0.5TC1.3 370 120 1000 0.9 1.12 2.3 cnbd 100 cnbd E1.4 Ni1.5Mo0.5W0.5, 3 wt% Lap TC1.4 370 120 1000 1 1.22 2.7 6 128 110 C1.4 Ni1.5Mo0.5W0.5 TC1.4370 120 1000 1 1.12 3.9 11 100 100 ULSD E1.5 Ni1.5Mo0.5W0.5, 3 wt % LapTC2.1 320 45 300 2 1.27 0.7 0.3 167 103 C1.5 Ni1.5Mo0.5W0.5 TC2.1 320 45300 2 1.20 2.2 0.4 100 100 E1.6 Ni1.5Mo0.5W0.5, 3 wt % Lap TC2.2 320 45300 2.25 1.27 3.2 0.4 156 104 C1.6 Ni1.5Mo0.5W0.5 TC2.2 320 45 300 2.251.20 8.6 0.5 100 100 Cnbd = Could not be determined.

Example E2 Ni1W1+3 w % Laponite

1.8 g laponite (LOT=11.2%, Laponite RD available from Rockwool AdditivesLimited) was suspended in water in a separate stirred vessel forapproximately one hour. 50.0 g of tungstic acid H₂WO₄ (0.2 mole W) wasslurried in one liter of water together with 23.5 g of nickelhydroxycarbonate 2NiCO₃*3Ni(OH)₂*4 H₂O (0.2 mole of Ni). Then thelaponite suspension was added and the mixture was stirred until theslurry became homogeneous. The suspension was heated to 95° C. and heldat that temperature for a period of 24 hours (overnight) with continuousstirring. At the end of this time, the suspension was filtered. Theresulting solid was dried at 120° C. for 16 hours (overnight). Theresulting solid was pelleted, the pellets were crushed and 40-60 meshfraction was isolated by sieving. The material was then calcined at 300°C. for 1 hour. The material was then sulfided and tested as describedbelow in Test Procedure 3.

Example E3 Ni1Mo0.5W0.5+3 w % Laponite

The same catalyst as Example 1 was sulfided and tested as describedbelow in Test Procedure 3.

Comparative Experiment C2 Ni1Mo0.5W0.5 No Laponite

The same catalyst as Comparative 1 was sulfided and tested as describedbelow in Test Procedure 3.

Comparative Experiment C3 Ni1W1 No Laponite

A catalyst was prepared as described in Example E2, however without theaddition of laponite suspension. The catalyst was sulfided and tested asdescribed below in Test Procedure 3.

Comparative Experiment C4 Ni1W1 No Laponite—150° C.

A catalyst was prepared in a procedure similar to that of Comparativeexample C3, except the reaction was carried out at 150° C. in anautoclave heated with microwave radiation, under autogenic pressure forabout 6 hours, instead of 95° C. under atmospheric pressure in an openvessel for 24 hours. 2.35 g of Ni carbonate (0.02 moles Ni) was added to100 cc of water along with 4.99 grams of tungstic acid (0.02 mole W).The suspension was put into a sealed Weflon™ vessel of 275 cc totalvolume and heated with microwave radiation at 10° C./min to 150° C. andheld under autogenic pressure at that temperature for 6 hours withcontinuous stirring. The sample was cooled to room temperature and thesolid filtered and dried overnight at 120° C. The obtained material waspelleted, the pellets were crushed and a 40-60 mesh fraction wasisolated by sieving. The material was then calcined at 300° C. for 1hour. The material was then sulfided and tested using Test Procedure 3.

Comparative Experiment C5 Ni1W1 No Laponite—90° C., 7 Days

A catalyst was prepared in a procedure similar to that of Comparativeexample C3, except the reaction was carried out at 90° C. in an openvessel for 7 days.

50.0 g of tungstic acid H₂WO₄ (0.2 mole W) was slurried in one liter ofwater together with 23.5 g of nickel hydroxycarbonate 2NiCO₃*3Ni(OH)₂*4H₂O (0.2 mole of Ni). The suspension of the 2 solids was heated to 90°C. and held at that temperature for a period of 7 days with continuousstirring. At the end of this time, the suspension was filtered. Theresulting solid was dried at 120° C. for 16 hours (overnight). Theresulting solid was pelleted, the pellets were crushed and a 40-60 meshfraction was isolated by sieving. The material was then calcined at 300°C. for 1 hour. The material was then sulfided and tested using TestProcedure.

Test Procedure 3 Diesel

The catalysts E2, E3 and C2 to C5 were tested in a diesel hydrotreatmentprocess in a down-flow tubular reactor. Each reactor tube contained 10ml of catalyst mixed with an equal amount of SiC particles andsandwiched between layers of SiC particles. Before being tested thecatalysts were presulfided via liquid phase presulfiding using the feeddescribed in Table 4 which had been spiked with dimethyl disulfide to atotal sulfur content of 3.7 wt. %. The presulfided catalysts were thentested in the hydrotreatment of a diesel feedstock having the propertiesshown in Table 4.

TABLE 4 GAS OIL FEEDSTOCK S (wt. %) 1.1969 N (ppm wt) 102 totalaromatics (wt. %) 28.3 mono-aromatics (wt. %) 16.5 di-aromatics (wt. %)11.0 tri+-aromatics (wt. %) 0.8 Simulated distillation ASTM-D 86 Initialboiling point 178.4° C.    5 vol. % 211° C. 10 vol. % 224° C. 30 vol. %261° C. 50 vol. % 283° C. 70 vol. % 309° C. 90 vol. % 348° C. Finalboiling point 372° C.

The catalysts were tested under the two conditions shown in Table 5. Thetest results are given in Table 6, wherein suffix 1 and 2 after HDS,HDN, N and S refer to Conditions 1 and 2 given in Table 5.

TABLE 5 Presulfiding Condition 1 Condition 2 Temperature (° C.) 320 320340 Pressure (bar) 45 45 20 H₂ to oil ratio (Nl/l) 200 300 300 LHSV(1/h) 3.00 3.00 1.50

The results presented in Table 6 show that nanosized clays allows thepreparation of catalysts with superior hydrotreating performancesrelative to catalysts prepared without nanosized clays, even when longreaction times or hydrothermal conditions are used in the absence ofnanosized clays.

TABLE 6 CBD S1 S2 N1 N2 RVA RVA RVA RVA sample composition test loadedppm ppm ppm ppm HDS1 HDS2 HDN1 HDN2 E2 Ni1W1 + 3 w % laponite TC3 1.530.7 0.8 0.3 1.3 403 155 110 139 E3 Ni1Mo0.5W0.5 + TC3 1.27 7.7 2 0.4 3.8140 104 106 105 3 w % laponite C2 Ni1.5Mo0.5W0.5 TC3 1.25 15.7 2.2 0.54.4 100 100 100 100 C3 Ni1W1-95° C./1 day TC3 1.12 159 20.6 27 29 26 3625 38 C4 Ni1W1-150° C. TC3 1.72 0.9 0.9 0.3 1.4 347 151 110 130 C5Ni1W1-90° C./7 days TC3 1.51 6.7 1.7 0.3 2.9 148 112 105 102

Example E4 Ni1W1+10 wt. % Laponite

7.3 g laponite (LOT=11.2%, Laponite RD available from Rockwool AdditivesLimited) was suspended in one liter of water in an open stirred vesselfor approximately one hour. As mentioned in Example E1, the laponiteused in this example is formed of primary particles that are disc-likeplatelets of about 0.92 nm thickness and having a lateral dimension ofabout 25 nm. According to the manufacturer the laponite has a surfacearea of over 900 m²·g⁻¹. 49.9 g of tungstic acid H₂WO₄ (92.7 wt. % WO₃,0.2 mole W) and 23.5 g of nickel hydroxycarbonate 2NiCO₃*3Ni(OH)₂*4 H₂O(0.2 mole of Ni) were added to the laponite suspension while stirring.The mixture was stirred until the slurry became homogeneous. Thesuspension was heated to 90° C. and held at that temperature for aperiod of 20 hours, while stirring. The pH of the suspension measured5.7. At the end of this time, the suspension was filtered. The resultingsolid was dried at 90° C. overnight. X-ray diffraction of the resultingsolid showed the typical features of the catalyst according to theinvention, as shown in the top XRD pattern of FIG. 2.

Comparative Example C6 Ni1W1+10 wt. % Actigel 208

The procedure of Example E4 was repeated, except Actigel 208 was usedinstead of laponite. Actigel 208 is a high quality, purified,self-dispersing natural clay having rod-shaped particles that average athickness of about 3 nm and a lateral dimension of about 2 microns. TheX-ray pattern of the resulting solid is shown in the bottom XRD patternof FIG. 2 and shows peaks characteristic of unreacted metal speciesrather than the characteristic pattern of the desired bulk metalparticles.

What is claimed is:
 1. A method for hydroprocessing hydrocarbonfeedstocks, said method comprising contacting a hydrocarbon feedstockunder hydroprocessing conditions with a bulk catalyst compositioncomprising bulk metal particles, wherein said bulk metal particlescomprise at least one Group VIII non-noble metal and at least one GroupVIB metal, said metals being in the form of oxides, sulfides, or acombination of oxides and sulfides, and nanoparticles having a dimensionof less than 1 μm, said nanoparticles being different in compositionfrom said Group VIII non-noble metal and Group VIB metal oxides,sulfides, or combination of oxides and sulfides.
 2. The method of claim1, wherein the combined weight of Group VIII non-noble metal and GroupVIB metal in said bulk metal particles, calculated as weight of metaloxides relative to the total weight of bulk metal particles, representsfrom 50 wt. % to 99.5 wt. % of the total weight of the bulk metalparticles; and, the weight of nanoparticles in said bulk metal particlesrepresents from 0.5 wt. % to 15 wt. % relative to the total weight ofthe bulk metal particles.
 3. The method of claim 2, wherein the combinedweight of Group VIII non-noble metal and Group VIB metal in said bulkmetal particles, calculated as weight of metal oxides, represents from70 wt. % to 99 wt. % relative to the total weight of the bulk metalparticles.
 4. The method of claim 2, wherein the weight of nanoparticlesin said bulk metal particles represents from 0.75 to 10 wt. %, relativeto the total weight of the bulk metal particles
 5. The method of claim2, wherein the weight of nanoparticles in said bulk metal particlesrepresents from 1 to 5 wt. %, relative to the total weight of the bulkmetal particles.
 6. The method according to claim 1, wherein thenanoparticles are platelets having a thickness of 0.1 to 1.5 nm, anaspect ratio of 100 to 1500 and a surface area greater than 250 m²/g. 7.The method according to claim 1, wherein the nanoparticles are selectedfrom the group consisting of synthetic clays of the smectite family,layered silicic acids, kaolinite, laponite, halloysite and mixturesthereof.
 8. The method according to claim 1, wherein the nanoparticlesconsist essentially of laponite.
 9. The method according to claim 1,wherein the at least one Group VIII non-noble metal is cobalt and/ornickel and the at least one Group VIB metal is molybdenum and/ortungsten.
 10. The method according to claim 1, wherein the metalspresent in the bulk metal particles consist essentially of nickel,tungsten and molybdenum.
 11. The method according to claim 1, whereinthe metals present in the bulk metal particles consist essentially ofnickel and tungsten.
 12. The method according to claim 1, wherein thebulk metal particles further comprise a Group V metal.
 13. The methodaccording to claim 1, wherein said hydroprocessing conditions includetemperatures ranging from about 100° C. to about 450° C., liquid hourlyspace velocities (“LHSV”) from about 0.05 to about 20 hr−1, pressuresfrom about 5 to about 250 bar, and a hydrogen (H2) to oil ratio fromabout 18 to about 1800 m3/m3 (100 to 10000 SCF/B).
 14. The methodaccording to claim 1, wherein the hydrocarbon feedstock has a boilingrange of from about 150° C. to about 650° C.
 15. A method forhydroprocessing hydrocarbon feedstocks, said method comprisingcontacting a hydrocarbon feedstock under hydroprocessing conditions witha bulk catalyst composition comprising bulk metal particles, whereinsaid bulk metal particles have been prepared by a manufacturing processcomprising the steps of combining in a reaction mixture (i) dispersiblenanoparticles having a dimension of less than about 1 μm upon beingdispersed in a liquid, (ii) at least one Group VIII non-noble metalcompound, (iii) at least one Group VIB metal compound, and (iv) a proticliquid; and reacting the at least one Group VIII non-noble metalcompound and the at least one Group VIB metal in the presence of thenanoparticles, wherein said dispersible nanoparticles differ incomposition from said Group VIII non-noble metal and Group VIB metalcompounds.
 16. The method according to claim 15, wherein the metalcompounds are at least partly in the solid state during the process ofmanufacturing the bulk metal particles.
 17. The method according toclaim 16, wherein the nanoparticles are added to the reaction mixtureafter the combination of the metal compounds.
 18. The method accordingto claim 16, in which the reaction mixture is prepared by: a) preparinga first suspension of the at least one Group VIII non-noble metalcompounds in a protic liquid; b) preparing a second suspension of the atleast one Group VIB metal compounds in a protic liquid; and, c)combining the first and second suspensions; wherein either the first,second, or both the first and second suspensions contain thenanoparticles.
 19. The method according to claim 18, wherein said atleast one Group VIII non-noble metal compound comprises nickel carbonateor nickel hydroxycarbonate precipitated in the presence of nanoparticleshaving a dimension of less than 1 μm.
 20. The method according to claim15, wherein the bulk metal particles obtained after reaction aresubjected to one or more of the following steps: a) compositing the bulkmetal particles with a material selected from the group consisting ofbinder materials, conventional hydroprocessing catalysts, crackingcompounds or mixtures thereof; b) spray-drying, (flash) drying, milling,kneading, slurry-mixing, dry or wet mixing or combinations thereof; c)shaping; d) drying and/or thermally treating; or e) sulfiding.